How to weld aluminum with a tig?

Clean aluminum, use a TIG welder on AC mode, set proper amperage, maintain the right torch angle, and add the appropriate filler rod.

Safety Precautions

Personal Protective Equipment (PPE)

Welding, particularly with techniques like TIG welding, poses certain risks that require the use of specialized protective equipment. Using the right PPE not only ensures the safety of the welder but also contributes to the efficiency and quality of the welding process.

Helmets and Eye Protection

When TIG welding, it’s crucial to protect the eyes and face from the intense light and UV radiation. Modern welding helmets come with auto-darkening features, and for aluminum TIG welding, a shade level between 10 to 13 is recommended. An auto-darkening helmet with a reaction speed of 1/25,000 of a second can cost anywhere between $100 to $500, depending on brand and additional features. Always inspect your helmet for cracks or damages before use. Read more about welding helmets on Wikipedia.

Welding Gloves

Welding gloves are specifically designed to resist heat and provide the dexterity needed for TIG welding. For aluminum, it’s ideal to have gloves made from a material like goatskin which offers a good balance of protection and dexterity. A good pair can range from $20 to $100.

Protective Clothing

Clothing should be made from flame-resistant material like leather or specially-treated cotton. Avoid synthetic materials as they can melt onto the skin. A quality welding jacket can cost anywhere from $30 to $200. It’s also important to wear closed shoes, preferably made of leather.

How to weld aluminum with a tig

Workspace Safety

The environment in which welding takes place plays a crucial role in ensuring safety and quality outcomes.


Aluminum welding can produce fumes that may be harmful if inhaled. Ensure that the workspace is well-ventilated, or use a fume extraction system. The cost of a basic extraction system starts at around $500.

Clutter-Free Space

A cluttered workspace can lead to accidents. Ensure all tools and materials are organized, and unnecessary items are kept away. The welding area should be spacious, with at least a 10×10 ft working space.

Fire Safety

Have a fire extinguisher rated for metal fires within arm’s reach. Considering the materials involved, a Class D fire extinguisher is recommended, and these can range from $100 to $600 based on capacity and brand. Check out the fire extinguisher Wikipedia page for more information.

Electrical Safety

Electrical safety is paramount when dealing with TIG welders, as they operate at high voltages.

Equipment Inspection

Before starting, always inspect the welder, cables, and connectors for any signs of wear or damage. A faulty cable can be a significant safety hazard.


Ensure that the welding machine is properly grounded. This is crucial in preventing electric shocks. The grounding cable should be connected to a dedicated grounding rod or a verified ground source.

Power Settings

Set the welder to the appropriate power settings for aluminum. Typically, a power range of 100-250 A is used for aluminum welding, but this can vary based on thickness and specific alloy. Adjusting to the wrong power setting can lead to inefficient welds or burn-through.

Avoid Water

Water is a conductor of electricity. Always ensure that the workspace is dry. If using a water-cooled TIG torch, regularly check for leaks, as this can pose an electrical risk. A quality water-cooled torch system can range in price from $200 to $800.

Remember, investing in safety is never a waste. It ensures the longevity of equipment, the quality of the weld, and most importantly, the well-being of the welder.

Equipment and Materials Needed

Selecting the Right TIG Welder

Brand and Reliability

When choosing a TIG welder, it’s vital to consider reputable brands known for producing reliable machines. Brands such as Miller, Lincoln, and Hobart have established themselves in the welding industry. A reliable mid-range TIG welder suitable for aluminum can range between $1,500 to $3,000.

Power Output and Duty Cycle

Consider the welder’s power output and duty cycle. For aluminum welding, a machine capable of delivering between 150-250 A is typically sufficient for most tasks. A duty cycle of at least 60% at 200 A is advisable for consistent work. For more on duty cycles, see the Wikipedia page on Duty cycle.

AC/DC Options

Aluminum welding requires the AC (Alternating Current) option. Ensure the machine offers both AC and DC for versatility. The AC option is essential to break through the aluminum oxide layer during welding.

Aluminum Filler Materials

Type of Aluminum Alloy

The choice of filler material depends on the type of aluminum alloy you’re welding. For instance, 4043 is a common filler for 6061 aluminum. If unsure, always refer to a filler metal chart to match the base metal with the appropriate filler.

Diameter and Length

Filler rod diameters typically range from 1/16″ to 3/16″, with the choice depending on the material’s thickness. A 1/8″ rod is a versatile option suitable for many tasks. Rods are commonly available in 36-inch lengths and can cost between $10 to $40 per pound, depending on the alloy.

Shielding Gas: Argon vs. Helium


Argon is the most commonly used shielding gas for aluminum TIG welding. It offers good arc stability and a clean weld. A standard size tank of Argon, around 125 cf, can range between $300 to $500, including gas.

Helium or Argon-Helium Mix

Helium provides more heat and a faster travel speed, making it ideal for thicker materials. However, it’s also more expensive. An Argon-Helium mix can offer a balance, providing additional heat without the full cost of pure helium. Helium costs can be up to 50% more than Argon, so use it judiciously.


Tungsten Electrode Choices

Type of Tungsten

For aluminum, the green-coded pure tungsten or the blue-coded 2% lanthanated tungsten are popular choices. Learn more about Tungsten electrodes on Wikipedia.

Diameter Selection

Tungsten diameters can range from 0.040″ to 1/4″. For general aluminum work, especially with a thickness of up to 1/8″, a 3/32″ diameter tungsten is commonly used.

Electrode Prep

Ensure the tungsten electrode has a balled tip when welding aluminum. This can be achieved by setting the TIG welder to AC and striking an arc on a piece of clean copper until the tip balls up.

Preparation Steps

Cleaning Aluminum Surfaces

Importance of a Clean Surface

For a successful aluminum TIG weld, the base metal’s cleanliness is paramount. Aluminum naturally forms an oxide layer that can impede the welding process.

Using Acetone or Isopropyl Alcohol

To begin, wipe down the aluminum surface using a clean cloth soaked in acetone or isopropyl alcohol. These solvents effectively remove oils, grease, and other contaminants. A quart of acetone typically costs between $8 to $12 at most hardware stores.

Wire Brushing

After the solvent cleaning, use a stainless steel wire brush dedicated solely to aluminum to further clean the surface. This brushing removes the thin layer of aluminum oxide. Always brush in the direction of the grain to avoid embedding contaminants. A good quality wire brush can be bought for around $5 to $15.

Setting up the TIG Welder

Selecting the Correct Polarity

Ensure that the TIG welder is set to AC (Alternating Current) when welding aluminum. The alternating current helps in breaking down the aluminum’s oxide layer, which has a higher melting point than the base metal. This detail can be found in the welder’s manual or on the machine panel.

Adjusting Amperage

Depending on the thickness of the aluminum, adjust the machine’s amperage. As a general rule, use 1 amp for every 0.001 inch of material thickness. For instance, for a 1/8 inch thick piece (or 0.125 inches), you would set the machine around 125 amps.

Setting the Balance Control

Modern TIG welders come with a balance control feature for AC welding. For aluminum, a balance setting of 65-75% is a good starting point. This setting controls the amount of cleaning (oxide removal) versus penetration. You can find more details on TIG welding on Wikipedia.

Configuring Gas Flow Rates

Choosing the Right Gas

For aluminum TIG welding, 100% argon is the most common shielding gas choice due to its good arc stability and cleaning action.

Adjusting the Flow Rate

The flow rate for TIG welding usually ranges between 10 to 20 cfh (cubic feet per hour). For most general aluminum welding tasks, setting the flow rate to 15 cfh provides an optimal shield while conserving gas.

Checking for Leaks

Always ensure there are no leaks in your gas lines or connections. A small leak can quickly deplete a tank, leading to additional costs and interrupted work. Regularly inspect hoses for wear, cracks, or other damages.

Welding Techniques

Strike the Arc Properly

Importance of a Clean Start

Initiating the arc correctly is fundamental for a quality weld. An improperly struck arc can introduce contaminants and lead to a weak starting point.

Lift-Arc Start

Lift-arc start is a technique where the tungsten electrode is lightly touched to the workpiece, and as you lift it, the arc initiates. This method is less damaging to the tungsten compared to scratch starting.

High-Frequency Start

Modern TIG welders often come with a high-frequency (HF) start feature, which allows the arc to start without touching the tungsten to the metal. It’s a non-contact method that ensures the tungsten remains uncontaminated. Utilize this feature if available on your machine.

TIG Welding Aluminum Butt and Tee

Puddle Formation and Control

Observing the Puddle

Once the arc is struck, focus on the weld puddle’s formation. For aluminum, the puddle should appear shiny and fluid. This appearance indicates that the oxide layer has been broken and the base metal is ready to be fused.

Controlling the Puddle

Use the foot pedal or hand control to modulate the power and, consequently, the heat input. If the puddle appears too fluid or uncontrollable, reduce the amperage. Conversely, if the puddle is not forming adequately, increase the amperage slightly.

Travel Speed and Torch Angle

Maintaining Consistent Speed

Consistency is key when it comes to TIG welding. Moving too fast can lead to inadequate penetration, while moving too slow can result in excessive heat input and potential burn-through. A typical travel speed for TIG welding aluminum might be around 6 to 8 inches per minute, but this can vary based on material thickness and other factors.

Torch Angle

Maintain a torch angle between 10 to 15 degrees from vertical in the direction of travel. This angle allows for optimal shielding gas coverage and directs the heat appropriately into the workpiece. Check out the detailed techniques on TIG welding on Wikipedia.

Adding Filler Rod

Timing the Addition

Once a proper puddle has formed, start adding the filler rod. Add the filler to the leading edge of the puddle, ensuring you’re not touching the tungsten.

Choice of Filler

The filler rod’s diameter and type should align with the base material. For example, a common choice for 6061 aluminum is the 4043 filler rod.

Feeding Technique

Hold the filler rod at a 15-degree angle to the workpiece. Dip the rod in and out of the puddle, ensuring a consistent bead formation. The speed at which you add the filler depends on the material’s thickness and the desired bead profile.

Common Challenges and Troubleshooting

Dealing with Porosity

Identifying Porosity

Porosity manifests as tiny pinholes or cavities in the finished weld. In aluminum TIG welding, porosity can be caused by various factors, including contamination, improper shielding gas, or a too-extended arc length.

Prevention Measures

To reduce the risk of porosity:

  • Ensure the material is clean. Any oil, dirt, or oxide layer can introduce contaminants.
  • Use 100% argon as the shielding gas and ensure a proper flow rate of around 15 cfh.
  • Maintain the right arc length, typically around the same distance as the diameter of the tungsten electrode you’re using.

Remedying an Affected Weld

If a weld is affected by porosity, it may compromise its structural integrity. In such cases, it’s advisable to grind down the porous section and re-weld, ensuring all preventative measures are in place.

Preventing Burn-through

Recognizing Burn-through

Burn-through occurs when too much heat is applied to the metal, causing it to melt excessively and create a hole. This is especially a concern with thin aluminum sheets, which can easily be compromised by excessive amperage or slow travel speed.

Solutions and Tips

  • Adjust the amperage according to material thickness. A general guideline is 1 amp for every 0.001 inch of material thickness.
  • Increase travel speed if you notice the puddle becoming too large or uncontrollable.
  • Use a backing material or copper backer to help dissipate heat on thinner materials.
  • Practice on scrap material to find the right balance of amperage and travel speed for your specific task.

Professional Tig Welding Aluminum Job Work

Addressing Tungsten Contamination

Causes of Contamination

Tungsten contamination occurs when the tungsten electrode touches the molten weld pool or filler metal, introducing tungsten particles into the weld. This results in a weaker weld and may produce visible inclusions or a rough weld bead surface.

Preventive Techniques

  • Ensure you maintain a consistent arc length. Holding the torch too close or dipping the tungsten can lead to contamination.
  • Use a high-frequency start to initiate the arc without making contact.
  • Keep a steady hand. Utilizing a TIG finger or a rest can help stabilize the torch and prevent unintended contact.

Correcting Contaminated Welds

If you suspect tungsten contamination:

  • Stop welding and allow the area to cool.
  • Grind away the contaminated section until you reach clean metal.
  • Sharpen or replace the tungsten electrode.
  • Restart the weld, ensuring to take precautions against further contamination.

Post-Welding Procedures

Cleaning the Weld

Importance of a Clean Finish

After completing the weld, it’s essential to clean the area to remove any residues, ensuring both the aesthetic appeal and integrity of the weld.

Using a Wire Brush

Brushing the weld with a stainless steel wire brush will help remove any soot or residue. It’s crucial to use a brush dedicated solely to aluminum to prevent cross-contamination. A quality wire brush costs between $5 to $20, depending on the brand and size.

Chemical Cleaning

This solution can cost around $10 to $30 per quart. Always wear gloves and safety glasses when handling chemicals.

Inspecting for Defects

Visual Inspection

Start with a visual inspection of the weld. Look for any inconsistencies in the bead, discoloration, or signs of contamination. A magnifying glass or inspection mirror can be useful for hard-to-see areas and costs between $5 to $50 based on magnification and quality.

Using Penetrant Testing

For critical applications, a dye penetrant test can reveal surface defects not visible to the naked eye. This method involves applying a dye to the weld, letting it sit, and then wiping it off. Any defects will absorb the dye, making them visible.

Stress Relieving and Heat Treatment

Why Stress Relieving?

Welding introduces heat and stress into materials. Over time, these stresses can lead to distortion or failure, especially in applications where the weld will bear significant load or undergo frequent temperature changes.

Heat Treating Process

Heat treating involves heating the welded area to a specific temperature, then cooling it at a controlled rate. For aluminum, the typical stress-relieving temperature ranges from 650°F to 800°F. The time and exact temperature depend on the specific aluminum alloy.

Equipment and Costs

To perform stress-relieving or other heat treatments, an industrial oven or furnace capable of maintaining precise temperatures is needed. These can range from $2,000 for a basic model to over $10,000 for larger, more sophisticated units.

Benefits of Heat Treatment

Aside from relieving stresses, heat treatment can also improve the material’s mechanical properties, making the weld and surrounding area stronger and more resistant to cracking. Dive deeper into the heat treatment processes on Wikipedia to gain a broader understanding.

What's the optimal shielding gas for TIG welding aluminum?

The best shielding gas for TIG welding aluminum is 100% argon due to its good arc stability and cleaning action.

How much does a reliable TIG welder for aluminum cost?

A reliable mid-range TIG welder suitable for aluminum typically costs between $1,500 to $3,000, depending on the brand and features.

What amperage is recommended for welding 1/8 inch thick aluminum?

For 1/8 inch thick aluminum, set the machine around 125 amps.

Which filler rod is commonly used for welding 6061 aluminum?

A common choice for 6061 aluminum is the 4043 filler rod.

At what angle should the TIG torch be held during welding?

Maintain a torch angle between 10 to 15 degrees from vertical in the direction of travel.

What are the signs of tungsten contamination, and how can it be prevented?

Signs include a rough weld bead surface or visible inclusions. To prevent it, maintain consistent arc length and avoid touching the tungsten to the molten weld pool.

How much does a quart of acetone for cleaning aluminum cost?

A quart of acetone typically costs between $8 to $12 at most hardware stores.

What's the importance of stress-relieving after welding?

Stress-relieving helps to remove internal stresses introduced during welding, preventing distortion or failure, especially in load-bearing applications.

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