What Is Aluminum Welding Called?

Aluminum welding is often referred to as TIG welding (also called gas tungsten arc welding, GTAW), or MIG welding (also called gas metal arc welding, GMAW). Both refer to arc welding processes that can be used with aluminum, which has a low melting point and high thermal conductivity.

Fabricators use TIG for thin materials and exposed joints because it produces the cleanest, most controlled bead. MIG compromises some of that precision for speed, and is the best choice for thicker aluminum or production runs. Few shops still favor flux-cored arc welding (FCAW) for this metal, but it's toward the bottom of the list. There is no single “best” answer; it really depends on the job in front of you.

The Common Types of Welding Aluminum

Tungsten Inert Gas (TIG) Welding

TIG welding - Gas Tungsten Arc Welding (GTAW) - shows up everywhere where people want clean, crisp welds on aluminum. You have a tungsten tip that won't melt, a separate filler rod, and all of it takes place under a blanket of inert gas that keeps the weld clean and sharp. This is likely what you grab if you're working with thin aluminum or intricate joints.

Metal Inert Gas (MIG) Welding

MIG welding is everywhere in shops where speed and strength matter. It feeds a wire through a gun, and a shielding gas is fed along with it, so there are no messes. When it comes to thicker aluminum, MIG simply tears through faster than TIG. If you're working on something large and substantial, you definitely go with MIG, because it's fast, reliable, maybe not that pretty.

Flux-Cored Arc Welding (FCAW)

And then FCAW - flux-cored arc welding. It's like MIG except the flux is in the wire so you get your own shielding even when the wind is howling. FCAW can save the day when gas shielding is being blown away, and it's not the preferred method for aluminum (which is not the case most days). Not sexy, not typical of aluminum, but sometimes it has its moments.

Why Aluminum Is Hard to Weld

The aluminum surface has an oxide coating that melts at nearly 3,700°F, compared to the underlying aluminum's melting point of approximately 1,200°F. This gap is the cause of most aluminum welding problems. You need enough heat to break through the oxide layer without overheating the metal beneath it  - and the margin for error is thin.

The problem is exacerbated by heat conductivity. The heat is drawn from the weld pool about four times as quickly in aluminum as in steel, so a stable weld puddle may drop or burn through within the next second. New welders tend to attribute their problems to technique when the problem is really one of timing - aluminum has less time to change from solid to liquid.

It is important to clean the base metal prior to striking an arc with this material, unlike nearly all others. Oil, moisture, and oxide residue are all considered porosity in the completed weld and cannot be corrected after the weld has been made. Before welding, use a special stainless-steel wire brush (not one used on steel) to clean the joint.

TIG vs MIG for Aluminum

Both processes produce good aluminum welds but are used for different jobs.

TIG is a top-notch choice if you're building something where the weld shows, such as a custom motorcycle frame or a boat trailer. If you’re running thick plate for a trailer bed or structural bracket that will be painted or hidden, MIG gets you there faster with less setup. See our guide to MIG vs TIG welding for a more in-depth comparison.

What Is an Aluminum Welder Called?

The individual performing the task is just a welder, or an aluminum fabricator if they specialize in that. There is no dedicated job position for aluminum. What changes are the machine and the setup.

In the case of TIG welding, it's a TIG welder (a GTAW power source) paired with a tungsten electrode and argon gas. For MIG work, it is a MIG welder (GMAW power source) equipped with a spool gun or push-pull gun, as aluminum wire is not suitable for use with a standard steel setup.

The List of Tools Required for Welding Aluminum

Welding Machine

If you're working with aluminum, you need a TIG or MIG welder - the regular stuff doesn't cut it. These are the machines that actually make a weld happen. No power, no weld. Simple as that.

Torch or Welding Gun

It could be a TIG torch or a MIG welding gun, but it will be the heat and the filler that you will be concentrating on. There are no tricks, just steady hands and the proper equipment.

Electrode

A tungsten electrode hangs around TIG - it does not burn up. MIG? Not so much. This one is simply a spool of wire that becomes the weld. Both stimulate the aluminum with electricity, but in different ways.

Shielding Gas

You can't skip this part. If you don't use a shielding gas (typically argon for aluminum), your weld becomes a mess. The gas repels all that spoils a clean bead.

Filler Material

No matter what it's made of - rods or wires - you're adding this to get the aluminum parts to stick together. It's all about the right filler.

Welding Cart

Perhaps you could carry all of this around, but why do it yourself? Put your welder, tanks, and a bunch of accessories on a rolling welding cart and simply wheel the kit to the job. Protects your back and your mental health.

Tips for Welding Aluminum (for Beginners)

These are some of the habits that can determine whether the aluminum weld is clean or frustrating:

1. Clean the joint just before welding, not an hour before! When cleaned, aluminum re-oxidizes almost immediately.
2. Use a special wire brush for aluminum. One that has been touched by steel will contaminate the surface.
3. Thicker stock (1/4" and thicker) should be preheated to approximately 200-300°F to prevent heat from escaping from your weld pool before it melts.
4. Do not drag the torch or gun on MIG passes, push it. A push angle provides more shielding gas coverage and a flatter bead.
5. Keep an eye on your travel speed as much as your amps. If the puddle stays up for too long, it will collapse. So make sure to keep a consistent pace and do not stop mid-weld.

Frequently Asked Questions

Can aluminum be welded?

Yes, you can weld aluminum. But it's not as straightforward as welding something like steel. Because aluminum conducts heat so quickly and melts at a lower temperature, you have to be careful - melt it just a little too long, and it goes from solid to puddle in seconds.

Is aluminum welding hard?

Honestly, it is. If you're just starting out, aluminum can be a real pain: it warps, distorts, and generally refuses to behave. Still, if you put in the time - practice after practice - it eventually clicks. Skill isn't really optional here; you earn it one weld at a time.

Is TIG or MIG better for aluminum?

For thin material or joints that must be visible, TIG is the superior choice because of its control and cleanliness. MIG is faster and can be used to weld thicker material with less set-up time.

Is it possible to weld aluminum with a MIG welder?

Yes, but a spool gun or push-pull gun and straight argon gas are required. Aluminum wire is too soft to be fed through a standard steel MIG setup.

What is the name of a person who welds aluminum?

The person is a welder or aluminum fabricator. The machine is a TIG or MIG welder, the MIG is set up for aluminum wire.

Why is it difficult to weld aluminum?

Its oxide layer melts at almost 3,700°F, which is much hotter than the aluminum that is being melted, and it absorbs heat from the weld pool very rapidly. The combination makes time and cleanliness more important than with steel.

Can you stick weld aluminum?

It's not common to use Stick welding, or Shielded Metal Arc Welding (SMAW), for aluminum welding. Aluminum just isn't having it: too good at pulling heat away, too tough to shield properly. The flux-coated rod you need for stick welding? It struggles to keep a decent protective barrier, and your welds end up kind of sad. The real players with aluminum are TIG and MIG. Those are the ones that actually get the job done.

Conclusion

TIG welding provides clean, controlled seams on thin or exposed aluminum parts. MIG provides you with speed on thicker stock. Both require clean metal, the correct shielding gas, and equipment specifically designed for the aluminum process. After you have selected your process, the next issue you are likely to face is organizing your machine, tanks, and hand tools. Shop our welding carts to create a station that has everything within reach.