How to Get Great Aluminum Welding Results

Aluminum is one of the popular metals to use for welding because of its excellent properties—it's lightweight, strong, durable, and easily worked. Aluminum has a melting point of nearly 1,220ºF (660ºC), and it is the best conductor of both heat and electricity. Moreover, aluminum alloys easily with other metals, increasing its strength and durability.

However, aluminum workpieces often contain lead and copper additives that complicate the welding process by causing cracks. While this can be challenging, knowing the right techniques can help you achieve great welding results.

Aluminum Welding Methods

There are two primary methods for welding aluminum:

1. TIG welding aluminum
2. MIG welding aluminum

TIG Welding Aluminum

TIG welding aluminum is used when you require high-quality surface finishes. This method is ideal for repairing castings and welding pipes. Also know as Gas Tungsten Arc Welding (GTAW), this process uses of a non-consumable tungsten electrode to create the weld and requires a constant current power source.

TIG welding is preferred for thinner aluminum workpieces or which precise, clean welds are necessary.

MIG Welding Aluminum

MIG welding, a subtype of gas metal arc welding (GMAW), is known for its efficiency and speed, making it ideal for high-volume aluminum welding projects. The method requires very low heat and you will find less deformation in the welding portion.

MIG welding aluminum is suitable for thicker aluminum workpieces. The process is very fast and suitable for getting extensive and non-stop welds.

Plasma Cutting Aluminum

Although plasma cutting is not a welding process, it is an effective method for cutting aluminum before welding. Plasma cutting ensures precise cuts, keeps the surface outside the cutting area cool, and prevents the distortion or paint damage associated with flame cutters. This process can prepare aluminum workpieces for welding with minimal risk of warping or heat damage.

4 Tips for How to Achieve the Best Aluminum Welding Results

1. Prioritize Safety
Always follow safety protocols. Ensure that the welder and workpiece are properly protected during the welding process.
2. Maintain Focus
Unlike other processes, welding requires more care and concentration. Focus is key to achieving clean and accurate welds.
3. Handle High Temperatures with Care
The welder should be capable of handling the high temperatures, pressures, and stress associated with the welding process.
4. Brush the Weld Area
Aluminum welding can create imperfections. Use a steel brush to clean the weld area before and after welding to remove any oxides or contaminants.

Pulse arc technology paired with MIG welding is now widely recognized as an efficient technique for aluminum welding. It minimizes heat input, which leads to improved weld quality, particularly on thicker aluminum workpieces. Additionally, modern multi-process welders offer enhanced versatility and precision, making them ideal for a range of aluminum welding applications.