Aluminum Welding TIG

How you Start an aluminum weld makes THE difference

If you have been searching for the best tips for Aluminum Welding, TIG welding aluminum, or aluminum tig welding, you are in the right place.

Try these Tips for Aluminum TIG 

What is the best tungsten for tig welding aluminum?

I like to use 2% lanthanated tungsten for everything.

Aluminum, carbon steel, stainless steel, titanium...everything.

But that doesn't mean 2% lanthanated is the absolute best tungsten for every aluminum welding application. 

I like it because using one single color tungsten makes things simple and I don't fuss segregating different colors of tungsten.

CK LaYZr tungsten is also great for aluminum TIG welding at medium amperage ranges and also has good arc restarts.

The 3 c's or aluminum welding with TIG are 
1. clean
2. clean
3. clean

Aluminum needs to be clean for TIG welding. 

But how clean? the answer is ...it Depends.

Different applications require different levels of cleanliness prior to welding.

Brand new aluminum sheet might only need a quick wipe down with acetone.

But an aerospace test weld might need more thorough cleaning.

Aluminum that has been exposed to salt air will have a heavy layer of oxidation or even corrosion that needs to be removed prior to welding.

Argon flow rate and cup size and AC balance settings

Argon flow rate and cup size are related.  They both affect the cleaning zone of the arc.

Cleaning action comes from the electrode positive part of the AC current and AC balance settings let you adjust how much electrode positive is in the arc.

But cleaning action only goes where there is good argon coverage.

That is why its a good idea to test on a piece of scrap aluminum to tune your cup and argon flow rate.

What about plasma cut edges?

For best results, plasma cut edges need to be filed using a dedicated clean file that is appropriate for aluminum.

There are also flap discs designed for aluminum that will do a good job without loading up or embedding particles in the aluminum.

Cleaning your Aluminum filler metal

It is never a bad idea to wipe down your filler rod with acetone or alcohol.

Aluminum filler wire manufacturers sometimes use a lubricant when drawing the wire down to size.

A quick wipe with acetone ensures you are not adding impurities to the aluminum puddle.

you may not notice much difference in some brands of filler metal but wiping down filler rod is best practice.

Scroll down for links to more pages on Tig Welding Aluminum

This video shows revision 1 of the bike seat mod but also lots of clips with tips of aluminum welding tips using Tig.

Here are several other pages with tips for aluminum welding with TIG.

Ac balance setting for Tig

Description:  this videos explains AC balance settings

AC frequency applications

Description: a few applications for AC frequency adjustments on Aluminum

Aluminum welding vertical 3g butt joint

Description: This video shows tips for tig welding aluminum vertical uphill 3g position using .125"  (3mm) 6061 aluminum. 3/32" (2.4mm) 2% lanth electrode and 3/32" (2.4mm) 4043 filler rod

Welding aluminum horizontal 2g butt joint

Description: This video shows tips for tig welding an aluminum butt joint in horizontal 2g position using .125"  (3mm) 6061 aluminum. 3/32" (2.4mm) 2% lanth electrode and 3/32" (2.4mm) 4043 filler rod

Aluminum Tig Welding Drill

Description: This video shows tips for getting better at tig welding by tig welding aluminum beads on a plate...lots of them.

Right handed, left handed, long arc, short arc, lots of torch angle, and none, this is the time to try stuff pay attention to what works.

This excercise will keep that filler rod hand busy.