Welding Wisdom for Professionals and Beginners Alike.

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…

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…

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…

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,…

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…

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…

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…

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…

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…