How To Weld Aluminum With A TIG welder

I love the aluminum and tungsten gadgets because these things are lightweight, cooler, especially, they have an extended lifespan. Do you want to complete aluminum DIY projects on your own?

First, you have to know how to weld aluminum with a TIG welder. Everything else will be straightforward.

Table of Contents

How to weld aluminum with a TIG welder

Follow these seven steps, and you will reach the best outcome:

Step 1: Ensure safety

For any welding task, you must wear full of proper protective equipment including a welding jacket, safety glasses, gloves, and welding helmet.

Why?

The high reflection of aluminum and a significant amount of welding power will cause flying sparks and embers. Without protection, it may be harmful to your skin when exposing to these things.

Note:

You should consider the new helmet technology, which can improve the clarity and visibility of your weld.

Step 2: Clean aluminum

Like stick welder and MIG welder, TIG welder requires you to clean before welding since, over time, aluminum will contact with oxygen and form a layer of oxide.

Although it’s pretty harder to recognize than red oxidation on steel, oxidation on aluminum tends to change into dull silver color.

The most popular way to clean aluminum is to use a dedicated stainless steel wire brush or carbide cutter.

After cleaning, you should weld as soon as possible because that layer of oxide will reform immediately, obstructing your welding view.

Step 3: Adjust the balance control

When welding in AC polarity, your weld has two cycles: EN (electrode negative), and EP (electrode positive).

Any modern welding equipment allows you to adjust the balance control to see what you are welding.

Step 4: AC output frequency

The output frequency shows how many times per second the source of power switches polarity. The higher the AC output frequency is, the more stable the ARC is, which leads to tight and narrow ARC column.

More directional control allows you to weld in a tight space quickly and precisely.

Step 5: Apply suitable amperage

It’s possible to control amperage with your foot pedal or fingertip. I recommend you set a suitable maximum amperage.

Or let’s apply this rule:

Use one amp for every thousandth (0.001) of the thickness.

Specifically:

Apply 125 amp for base material (1⁄8 in. (0.125) thick).

Step 6: Set the AC Amperage Independently

This step helps you get more considerable penetration as well as productivity.

To achieve greater penetration, you should raise the amperage during the EN cycle.

Step 7: Add filler metal for the stacked-dimes look

When welding, adding filler metal helps you reach a stacked-dims look.

How can?

The solid filler metal will contact with a molten liquid at high heat.

If you want to produce a cooling effect on the backside of the weld puddle, add more filler rod to actas a heatsink.

For me, the following feature is not essential. But if you want, you can apply the foot pedal to adjust amperage for the stacked-dimes look.

Note: Attaching filler metal into torch speed or using welding torch for performing.

Try to do smooth movements for the best result.

Get welding now!

Aluminum welding with TIG welders helps you perform a lot of useful projects. Have you known how to weld aluminum with a TIG welder? Is it interesting? Can you let me know your experiences by leaving a comment below my post?