Even for experienced welders, welding aluminum and aluminum alloys can present a challenge. The higher thermal conductivity and low melting point of aluminum can easily lead to burn through or other problems. And thin gauge materials generally are more unwieldy to handle physically. DIY-er welders new to the material should take extra care and keep the following information in mind when working with aluminum.

Types of Welding Used for Aluminum

• Affordable gas metal arc (MIG) welders are more commonly part of the DIY arsenal
• Gas tungsten-arc (TIG) welders tend to be more expensive, but are better for thin gauge materials like aluminum

Tips for Welding Aluminum

• Choose the right electrode. Pure tungsten rod is the best choice for aluminum. Make sure the tip is clean and stop working immediately if the tip becomes contaminated, or you encounter snags. Aluminum is much less forgiving than steel when it comes to welding mishaps.
• Pure argon gas is the best fuel for aluminum welding though some experienced welders prefer a mix of helium and argon to create a hotter arc.
• Always prepare your metals properly before welding. For aluminum, use a wire brush to scrub surfaces clean of dirt or oxide. You can also use a blowtorch to pre-heat the metal to minimize distortion.
• Work quickly and keep the weld moving to prevent burn through.
• Accuracy is also more important with aluminum because it is so thin. You can’t go over and fill in gaps as you can with steel.
• Consider clamping a brass heat sink behind the aluminum to be welded. It takes some heat out of the weld and allows you work more slowly and accurately. This should ultimately result in a neater, cleaner weld.

Welding is a complex procedure that requires a steady hand and lots of practice. If your home improvement project involves aluminum, it may make sense to leave the welding to the pros at Domer’s Inc. The technicians at our state-of-the-art Okeechobee machine shop can handle any type of aluminum or steel welding with skill.