How to Weld Aluminum

Co-authored by wikiHow Staff | Reader-Approved | 22 References

Updated: March 29, 2019

Explore this ArticleAssembling Your MaterialsSetting up the Work SpacePracticing the Welding
MotionShow 1 more...Article SummaryQuestions & AnswersRelated Articles
Welding is the process of joining 2 metal components by melting them together. Welding
any material is a challenging process, but welding lightweight metals like aluminum
requires the utmost precision to ensure a strong bond. Knowing how to weld aluminum
is a matter of assembling the right tools, exercising caution and patience, and gaining
experience. First assemble your materials, practice the welding motion, and then set up
your work space.

1. Get a TIG (tungsten inert gas) welder with AC capability, not only DC. This is
a type of welder that uses a tungsten electrode and an inert gas to shield the
welding area.[1] The precision achieved with this type of welder is crucial when
working with aluminum, especially thin pieces.[2]
 TIG welders are expensive, so consider contacting a local welding supply store
or home hardware outlet about rental possibilities.
 It’s possible to weld aluminum with other welding processes, such as MIG
welding, but TIG welding is the method most suitable for beginners.

2
Acquire an aluminum filler rod. This tool is needed in order to bond the 2 pieces. Try
to avoid using rusty or dirty filler rods, as these will lead to weaker welds.
 You can find aluminum filler rods at hardware or home improvement stores, such
as Harbor Freight or Home Depot.
 Opt for either a 4043 or 5356 alloy.[3]
 Use a filler rod that is equal in size to the tungsten electrode. [4]

AC or DC—What’s the Difference?

Polarity describes which way the electricity is flowing. With direct current (usually called
DC), the polarity of the electric current always flows one way. The normal flow is
electrode negative, which means the electricity flows from the welder, through the
electrode, to the workpiece, and back to the welder. Reverse polarity turns that around
and drives the current from the welder through the workpiece to the electrode.

Direct current is favored for TIG welding most metals because it penetrates deeply.
Welding aluminum is one of the only times that alternating current is preferred.

Alternating current, or AC, flips the polarity between standard and reverse quickly, from
sixty to one hundred twenty times each second. Aluminum is usually TIG welded with
alternating current. The quick polarity flips have a sandblasting effect that breaks up the
surface oxides to produce a clean weld. The drawbacks to AC welding are that the weld
doesn’t penetrate deeply and that it leaves a large bead on the surface.

Why Use DC for Aluminum

The problem with AC welding is that the current does not penetrate deeply into the joint
and produces a shallow weld. If you are joining aluminum pieces that are ¼ inch thick or
more, AC won’t produce a strong weld in with just one pass.

To produce a strong weld in thick aluminum with alternating current, the welding is done
in steps. You have to bevel the edges of the joint, lay down a root bead, then come back
with one or more passes of filler and cap welds to get a strong joint. This requires three
or four passes with the welder before the joint is complete.

Reverse polarity DC welds don’t have this problem. You can get a good, deep weld joint
in one pass using DC welding. This saves time and produces a stronger weld.

DC welds are also useful for fixing deep pits and gouges in aluminum. You can quickly
fill a cavity with DC welding and get a strong joint that keeps the fill in place. Once the
hole has been filled, smooth the surface with a grinder, and the part is like new. This
helps fix expensive, machined aluminum parts that have become slightly damaged.

Use the Right Materials

Not every grade of aluminum is suitable for DC TIG welding. The best aluminum grades
for this process are 6061, 2219, and pure aluminum (everything in the 1100 series). If
you are working with other categories of aluminum, you may need to use AC to make
the weld.

In addition to using the right grade of aluminum, the correct dimensions are essential.
DC welding puts a lot of heat into the workpiece. If you try to DC weld thin stock, it can
overheat and warp. Direct current welding works best with pieces at least ¼ inch thick.
Besides the warping issue, the benefits of DC welding aluminum don’t come into play
until your stock anyway. Stick with AC for the thing stuff.