How To Weld Aluminum With A Mig Welder – You Can Do It

How To Weld Aluminum With A Mig Welder

Yesterday, when searching for information about alloy welding in some forums, I saw a status.

Here is the content:

“MIG (Metal inert gas) welding is a hard technique, which only pro welder can do it. Beginners should not try, especially girls.”

I completely disagree with this opinion.

Don’t do anything regarding welding when you haven’t learned about it carefully. But, once you have enough knowledge and careful preparation, let’s try. Whether you are a boy or a girl, you will find my guide on how to weld aluminum with a MIG welder helpful for beginners alike.

What you need to prepare

Protective items
Protective items

Before welding, you have to prepare  the following things for the best outcomes:

Welding machine

The thicker your metal is, the more powerful welding machine you need to look for.

Shielding gas

For aluminum welding, you should buy a shielding gas of pure argon, which is the combination of argon and carbon dioxide (CO2). This choice requires you to replace regulators designed for CO2, but you don’t have to buy new hoses.

Aluminum electrodes

The thickness of electrode plays a critical role in welding aluminum. While the too thin wire makes aluminum hard to feed, the thicker wire needs a larger current for melting.

The ideal size of electrodes for welding aluminum is 035 of an inch in diameter (under one mm). You can also use filler metal as a replacement.

Protective items

No matter what you weld, protective items are indispensable.

Make sure that you wear clothing which can cover your arms and legs as well. Especially, wearing a pair of gloves will help you avoid unwanted accidents for your hands. If you are careless, flying sparks and embers will harm your skin for sure.

Last but not least, wearing a faceplate ensures that you never look at the arc directly to avoid harming your eyes.

Step-by-step Instruction On How To Weld Aluminum With A Mig Welder

How To Weld Aluminum With A Mig Welder
How To Weld Aluminum With A Mig Welder

Cleaning your aluminum and electrodes

Before starting, remember to clean the aluminum by applying a few droplets of solvent like acetone or use a wire brush.

Use an aluminum feeding kit to feed the electrodes and soft aluminum wire.

Welding aluminum with a MIG welder

To perform correctly without being distorted, keep in mind the following features:

  • The contact tips need holes which are large enough to enter and small enough to offer electrical contact.
  • Aluminum requires a U-shaped drive roll that will not shave aluminum wire.
  • Add a non-metallic liner to minimize the friction on the wire.
  • Try to keep the gun cable as straight as possible since the soft wire tends to be kinked due to feeding restrictions than steel.
  • While performing, if your MIG welder has any issue, you can try to use lubricants for troubleshooting.

The advantages and disadvantages of aluminum MIG Welding

Like TIG welding, MIG welding technique also comes with benefits and drawbacks. Please take a look below:


  • Quick weld deposits
  • X-Ray quality welds
  • All-position welds


  • Requires special equipment
  • Has difficulties in welding thin aluminum
  • Needs good welding skills

It’s time to weld aluminum

Don’t have pressures that you are a beginner or a girl. No, it’s possible with my post. MIG welders are very straightforward. So, if you know how to weld aluminum with a MIG welder, you can handle several other projects in the future.

Is this experience interesting? Please let me know by leaving your comment below this post.

14 thoughts on “How To Weld Aluminum With A Mig Welder – You Can Do It”

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