Welding Wisdom for Professionals and Beginners Alike.

Dirty surfaces like dust, oil, or grease can cause spatter when MIG welding aluminum. Improper gas settings and high current levels may also increase spatter. Using the wrong electrode or…

Alternating current (AC) is the best choice for aluminum welding. Aluminum tends to oxidize, forming a layer of aluminum oxide that makes starting the arc difficult. AC helps remove this…

The color of tungsten for aluminum welding is usually green, which signifies pure tungsten. Welders may also use 2% thoriated tungsten (red) or lanthanated tungsten. Proper preparation is important; electrodes…

Use a DC stick welder for aluminum welding, as AC is not suitable. Apply DCEP polarity, which also works for steel. This method may produce more spatter and a difficult…

Welding aluminum using MIG and TIG processes produces ozone. This byproduct forms when ultraviolet radiation from the welding arc reacts with oxygen in the air. Additionally, using silicon filler in…

Argon is the main shielding gas for aluminum welding. It provides a cleaning action and good penetration. For 5XXX-series alloys, using a mixture of argon and helium (up to 75%…

For TIG welding aluminum, choose lens shades based on the amperage. Use shade 8-10 for up to 50 amps, shade 10 for 50 to 100 amps, and shade 12 for…

High-frequency (HF) voltage helps welding aluminum by delivering a high-voltage, low-current signal (5 to 10 MHz). This signal penetrates the aluminum oxide surface, allowing the welding arc to start. It…

For welding aluminum, the ideal frequency ranges from 120 to 200 Hz. This frequency improves arc control and travel speeds. Frequencies between 80 and 120 Hz can also be comfortable,…