May 29, 2023

What Is Aluminum Welding Called?

Aluminum melts at a relatively low temperature and conducts heat really well. Because of that, you can't just use any old welding approach if you want strong, long-lasting joints. You need techniques and tools made for the job. So let's break down the main types of aluminum welding, which methods actually work best, and what gear you'll need to get started.

The Common Types of Welding Aluminum

Tungsten Inert Gas (TIG) Welding

TIG welding - Gas Tungsten Arc Welding (GTAW) - shows up everywhere people want clean, crisp welds on aluminum. You've got this tungsten tip that doesn't melt, a separate filler rod, and all of it happens under a blanket of inert gas so the weld stays clean and sharp. If you're fussing over thin aluminum or complex joints, this is probably what you reach for. The results? Precise, sometimes a little too perfect, honestly.

Metal Inert Gas (MIG) Welding

Then there's MIG welding, absolutely everywhere in shops that care more about speed and strength than fussy details. It runs a wire through a gun, and a shielding gas follows along, so things don't get messy. Compared to TIG, MIG just rips through thicker aluminum in way less time. Fast, reliable, maybe not as pretty, but if you're building something big or heavy, you don't sit around debating.

Flux-Cored Arc Welding (FCAW)

And then FCAW - flux-cored arc welding. It feels like MIG, only the wire has flux inside, which means you get your own shielding even if the wind's howling. Not the go-to for aluminum (it just isn't, most days), but if you're stuck welding outdoors and gas shielding keeps blowing away, FCAW can bail you out. Not glamorous, not common for aluminum, but it has its moments.

What Is the Best Way to Weld Aluminum?

Picking the most suitable welding method isn't rocket science, but you do need to size up what the job really calls for. If you're after those clean, slick beads and you actually care what your welds look like (maybe you're working with thin stuff, or you want strength plus a bit of style), TIG's the way to go. It's slow and asks for a steady hand, but the results speak for themselves.

Got big chunky aluminum, or you need to move fast? MIG's faster, hangs in there when it comes to deeper welds, and you won't spend as long fumbling with technique. Don't expect the welds to look quite as sharp or tidy as TIG, but most people aren't staring at your seams anyway unless they're being picky.

The List of Tools for Welding Aluminum

To successfully weld aluminum, several essential tools are required:

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. Whether it's a TIG torch or a MIG welding gun, you'll be focusing the heat and feeding in the filler. No fancy tricks, just classic, steady hands and the right gear.
Electrode. TIG uses a tungsten electrode that hangs around for the whole job - it doesn't burn up. MIG? Not so much. That one's just a spool of wire that turns into the weld itself. Both sting the aluminum with current, just in different ways.
Shielding Gas. You can't skip this part. Without shielding gas-usually argon for aluminum-your weld turns into a disaster. The gas keeps out everything that ruins a clean bead.
Filler Material. Rods, wires, whatever form it comes in, you're adding this to get the aluminum parts to actually stick together. The right filler makes all the difference.
Welding Cart. Maybe you could lug everything by hand, but why punish yourself? Toss your welder, tanks, and a mess of accessories on a rolling welding cart and just wheel your kit to wherever the job is. Saves your back and your sanity.

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's a bit tricky. 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.

How to Store Welding Tools Properly?

If you want your welding tools to actually last (and honestly, who wants to replace them all the time?), you've got to store them right. That goes for everything - yep, even the stuff for aluminum.

First step: clean up your gear. Get rid of any grime, dust, or welding slag clinging to the tools before you put them away. Skip this, and you'll just end up fighting corrosion or weird sticky build-up down the line.
Moisture is the enemy here. Shove your tools in a damp corner and you'll have rust before you know it. Better to grab a proper tool cabinet or find a shelf that's dry - and stays that way.
Instead of tossing everything in a pile, actually organize - toolboxes, racks, or a wall pegboard all work. Label things if you're prone to forgetting where that one weird-sized wrench went. It saves a lot of digging and swearing later.
Some equipment is touchier than others - TIG torches, MIG guns, anything that gets fussy if you knock it around. Keep those in padded cases, or at least wrapped up so they're not banging into the rest.
Gas cylinders are their own beast. Store them standing, strap them down so nothing tips, and keep them out of hot spots or near stuff that can catch fire. Good ventilation matters - don't just shove them in a closet and forget about them.

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

So, aluminum welding: it's sort of its own world. TIG welding nails the neat, careful seams; MIG is just faster, and if you're dealing with chunky pieces, you want MIG. None of it works well if your gear's trashed. To keep things humming along, clean up your tools, keep them dry, and try not to lose track of stuff. Whether you're piecing together a thin sheet or a thick plate, good technique - and tools that aren't covered in grime - go a long way. Durable welds? Yeah, those are possible. But only if you actually respect the process.