How To Weld Aluminum With A Stick Welder – Never Need The Help 

How To Weld Aluminum With A Stick Welder

In the past, I had to spend tons of money on hiring a welder to fix some broken pieces of aluminum furniture. OMG! For some easy projects, THIS IS A WASTE.

At that time, I didn’t know that I myself can perform this task easily and quickly. In this post, I will share with you my experiences.

You can apply many techniques for aluminum welding, but today, I show the most effective way – how to weld aluminum with a stick welder.

What you need to prepare


Whether you want to perform Mig welding or stick welding, before learning how to weld aluminum with a stick welder, you have to prepare the essential gears as follow:


Let’s learn about the features of this material to deal with it properly. Aluminum material is pretty lightweight and soft, allowing you to cast, form, and weld effortlessly. That means you can join it with any metal by welding.

Sharp too or sandpaper

These things are used to scrape the thin layer of aluminum oxide. Over time, aluminum will get in touch with oxygen in the air, forming a thin layer of aluminum oxide, which needs removing before welding. If possible, it’s better to prevent the formation of this layer away from your aluminum.

A stick welder

Like TIG welding projects, you need a TIG welder. So, this welding also needs the best stick welder – a long-term investment because, in the future, you can use it to perform a lot of other engineering projects.

Protective gears

These things are especially more important for beginners with poor skills. Without protective gears, there may be an unwanted accident during the welding process.

The first items are hood and gloves for protecting your hands away from spatter. It’s better to wear a blow-out patch as well. A pair of protective glasses or shielding will keep your eyes away from dazzling.

Step-by-step guide on how to weld aluminum with a stick welder

how to weld aluminum with a stick welder
How to weld aluminum with a stick welder

Here is a step by step guide to follow:

Adjust the power level of the stick welder

Depending on the thickness of the material you will weld, let you adjust a suitable level between 190 and 210 amps.

While welding, it’s hard to control the ARC, and butt, especially, it’s difficult for fillet welds to be produced in a plate less than 1/8 in. (3.2 mm) thick. Thus, to weld plate heavier than 1/8 in., your joint must be at a 20-degree bevel.

Weld with electrode

Use an electric arc or electrode with inert gas for stick welding, which creates intense heat to melt the metal parts and join all of them together.

ARC welding aluminum is the current and polarity settings, which will vary depending on a typical type of electrode from the manufacturer. You can check the polarity by trial on the joints.

Control the welding rods properly

Try to perform the welding process as quickly and correctly as possible. Don’t let the metal contact with the ARC too much or it will cause the deformation for your pieces of aluminum.

Try to angle the welding rods at around 15 degrees against aluminum without holding straight up and down. If not, it’s hard to create a clean arc, and even your weld may be compromised.

Repeat these steps until you complete your complex structures.

Keep in mind this thing:

Controlling the ARC plays a vital role in the welding process. If you let the flux entrapment cause the corrosion, your welds may be prone to be failed easily.

Are you ready to weld?

How to weld aluminum with a stick welder? Have you found your own answer? Can you give me a picture of your project by leaving a comment below? Also, don’t forget to tell me about your wonderful experiences! I would be glad to answer all your questions regarding this problem.

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