How To Weld Aluminum With A TIG welder – Do Amazing Projects!

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.

Welding aluminum can be a challenge, but with the right techniques it can be done successfully. In this blog post, we’ll show you how to weld aluminum with a TIG welder. We’ll also provide some tips for getting the best results. So if you’re ready to learn how to weld aluminum like a pro, keep reading!

What is a TIG welder and what can it be used for?

A TIG welder is a machine that uses an electrical current to weld metal. It can be used for a variety of welding tasks, including joining two pieces of metal together, repairing metal objects, and creating new metal objects. TIG welders are often used in the automotive industry, as well as in other industries where metal objects need to be joined together.

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.


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.


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.


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.

Related – How To Adjust A Mig Welder Settings – The Best Beginner Guide 

What projects you can do with a TIG welder once you’ve learned how to weld aluminum?

Once you’ve learned how to weld aluminum with a TIG welder, there are a number of different projects you can tackle. For example, you could weld together pieces of aluminum tubing to create a custom frame or structure. Or, you could use your welding skills to fabricate a custom engine cover or other auto body part. If you’re feeling really ambitious, you could even weld together an entire aluminum boat hull. The possibilities are endless!

Tips and tricks for welding aluminum like a pro

If you’re new to welding aluminum, there are a few things you should keep in mind in order to weld like a pro. First, it’s important to use the correct type of filler rod. When welding aluminum, you should always use a ER5356 filler rod. This type of filler rod is specifically designed for welding aluminum and will help to ensure a strong, durable weld.

Another important tip is to make sure that your aluminum is clean before you start welding. Any dirt, grease, or other contaminants on the surface of the metal can prevent the weld from adhering properly. To clean the aluminum, simply use a wire brush or sandpaper to remove any unwanted materials.

Once you’ve got the hang of welding aluminum, you’ll be able to tackle all sorts of different projects. So have fun and experiment with all the different things you can do!

The benefits of welding aluminum with a TIG welder

First, TIG welding is extremely versatile and can be used on a variety of metals, including aluminum. Second, TIG welding produces very little heat, which means that it won’t distort the metal or cause warping. Third, TIG welding is very clean and doesn’t create any harmful fumes or smoke. Finally, TIG welding is fast and efficient, and can be used to weld aluminum quickly and easily.

The best way to learn how to weld aluminum with a TIG welder

Is to take a welding class or watch a few instructional videos. However, if you’re just starting out, it’s important to practice on some scrap metal first. This will help you get a feel for how the welder works and how to control the heat and arc. Once you’re comfortable with the basics, you’ll be able to weld aluminum


Do you TIG weld aluminum on AC or DC?

You can TIG weld aluminum on either AC or DC, but most people prefer to weld it on DC. This is because DC provides a more stable arc and produces less spatter than AC.

Is aluminum hard to TIG weld?

No, aluminum is not particularly hard to TIG weld. However, it is important to use the correct techniques and tools in order to avoid problems likeporosity or excessive spatter.

What color tungsten do I use for aluminum?

For welding aluminum, you should use a green tungsten electrode. This is because green tungsten provides the best arc stability and produces less spatter than other colors of tungsten.

What happens if you TIG weld aluminum with DC?

If you TIG weld aluminum with DC, the weld will be strong and have a good appearance. However, there may be some spatter and the weld may not be as smooth as it would be if you used AC.

Can you TIG aluminum with DC?

Yes, you can TIG weld aluminum with DC. However, most people prefer to use AC because it provides a more stable arc and produces less spatter.

Do you sharpen tungsten for aluminum?

Yes, you should sharpen the tungsten electrode before welding aluminum. This is because a sharp electrode will provide a more stable arc and produce less spatter.

How far should tungsten stick out?

For welding aluminum, the general rule of thumb is to extend the tungsten 1/16″ – 1/8″ beyond the end of the gas cup. This will help ensure that the arc is properly shielded and that you are able to get a good weld.

What tungsten is used for aluminum?

For welding aluminum, it is best to use a pure tungsten electrode. This will help ensure that you get a good weld and that the tungsten does not contaminate the weld.

Can you scratch TIG aluminum?

Yes, you can scratch TIG aluminum. However, it is best to avoid doing so as it can cause the weld to be compromised.

What is the best tungsten for TIG welding aluminum?

For welding aluminum, it is best to use a pure tungsten electrode. This will help ensure that you get a good weld and that the tungsten does not contaminate the weld.

Get welding now!

Tig welding aluminum can be a great way to join two pieces of metal together. If you’re new to the process, there are a few things you should keep in mind to make sure your welds are strong and look good. We’ve outlined the basics for you here, so that you can get started with confidence. Remember, practice makes perfect, so don’t be afraid to experiment a little as you learn. 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?

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