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When TIG welding aluminum, the amperage range depends on the aluminum thickness and tungsten diameter. Use 5-25 amps for 0.010”-0.035” thickness with 0.040” tungsten. For 1/16”, use 20-85 amps. For 3/32” to 1/4”, use 50-180 amps. For 3/16” to 3/8”, set it between 171-250 amps. Adjust settings to control temperature. Using an aluminum TIG welding … Read more

To weld aluminum with stick welding, set your welder to 50-80 amps for 3/32” 4043 electrodes, 80-130 amps for 1/8” electrodes, and 100-160 amps for 5/32” electrodes. Avoid using stick welding on aluminum thinner than 1/8”. For cleaner results, use AC TIG with argon shielding instead. Adjusting the arc length is essential. A shorter arc … Read more

Use a DC stick welder for aluminum welding. Choose DCEP polarity, like in steel or stainless welding. This will increase spatter and create a gummy weld puddle. Remember, aluminum has different properties than steel, so your stick welding experience will vary. Understanding these differences leads to better results in your projects. When welding aluminum, ensure … Read more

Aluminum stick welding needs careful amperage selection for best results. Common electrode sizes, like 1/8”, require an amperage range of 80 to 135 amps. This range helps maintain arc stability, manage temperature control, and reduce spatter. These factors contribute to a cleaner and more efficient welding process. Too low of an amperage can lead to … Read more

To prepare aluminum for welding, remove oil, grease, and moisture using acetone or an alkaline solution. Clean the surface to eliminate oxides with a wire brush. Ensure the area is dry to prevent porosity. Preheating may help but should not exceed 600°F. Proper cleaning is key for a strong weld joint. Proper fit-up is another … Read more

To achieve optimal aluminum MIG welding, adjust the voltage settings based on the filler wire diameter and transfer type. For short circuit transfer, set the voltage between 18-21 volts. For spray transfer, use 24-28 volts. Also, adjust the wire speed to match these settings. Refer to specific settings charts for further details on configurations. When … Read more

To achieve excellent aluminum MIG welds, follow these tips: 1. Prepare the metal well. 2. Preheat for better bonding. 3. Use aluminum-specific equipment. 4. Set the welder to spray transfer mode. 5. Use the push welding technique. 6. Fill craters properly. 7. Choose stiffer wire. 8. Manage the torch lead for straight movement. Adjust your … Read more

For .035 aluminum welding wire, set the voltage to 21-22 volts and the wire speed to 350-400 IPM for 1/8” thickness. For spray transfer, increase the voltage or lower the wire speed. Use pure argon as the shielding gas at 20 CFM. Set the machine to DC reverse polarity for MIG welding. Another key factor … Read more

Brazing is a strong alternative to welding aluminum. Instead of melting the aluminum, brazing uses a filler metal that melts at a lower temperature. This technique allows the filler to flow into the joint, securely joining the metals. Brazing reduces the risk of warping and preserves the aluminum’s structural integrity. Another option is mechanical fastening. … Read more

AC welding is generally better for aluminum. It effectively tackles aluminum oxide, which forms quickly. AC improves arc stability and penetration. This helps start and maintain the weld. While DC welding can be used, it often faces challenges with oxidation. For better welding efficiency on aluminum, choose AC over DC. On the other hand, DC, … Read more