Even if you are experienced in welding steels, learning how to weld aluminum can still be quite a challenge. The oxide coating, lower melting point and high thermal conductivity, can lead to problems unless you know to do through preparation and setting up the equipment.

While mig welding is used extensively in fabrication industries such as boat building, the most applicable for lighter gauge aluminum is tig welding both for strength and cosmetic appeal.

Welded aluminum is used for such applications as aluminum bicycle frames, wheel chairs, fencing and balustrades and aerospace work, also commercial airline engine casings, seat frames, ductwork, and any-where else where lightness and strength is required.

To weld aluminum, two main processes are generally used, Mig (GMAW) or Tig (GTAW) each uses different equipment and methods.

Mig & Tig Filler materials

Tig aluminum filler material is available in short easily handled lengths of about 500mm long, where as mig filler is aluminum welding wire on a feed spool, both come in various size diameters depending upon the aluminum to be welded. Keep filler material dry and free from oxidation and other contamination.  If you use your mig welder for welding steels and aluminum you will need to replace the inner cable liner and welding tip each time you switch processes, aluminum liners are usually made of Teflon, where as a metal liner is also metal. Using aluminum wire in a metal liner will result in contamination of the weld.

Work preparation

Aluminum work must be cleaner than steel work pieces to be welded effectively. The first step is to remove oils and greases from the work piece by wiping the area with a solvent or washing it with a mild alkaline solution. The second step is to remove all oxides, which can be done with a stainless steel wire brush. Never use the same brush on aluminum and steel or it will become contaminated.

Not only do you need to clean well before beginning, but you also should remove the smut or soot between  passes. This soot is fine particles of aluminum oxide and magnesium oxide. Proper welding techniques will minimize the amount of soot produced.

Shielding Gas

usually, 100 percent argon gas is preferred for aluminum GTAW, but when working with thicker materials, such as 1/2 inch or greater, add helium in the range of 25 to 50 percent. Helium makes the arc hotter and provides for more penetration.

Torches and mig guns

if the application is light-duty fabrication requiring up to 150 amps, an air-cooled torch or hand piece may suffice. Higher-amperage jobs require a water-cooled torches and hand pieces. One feature to look for in a good torch is a flexible head, which offers maneuverability and reaches tight areas. Trying to access tight areas is a main drawback to using a mig set-up due to the size of the gun or hand piece.

When you learn how to weld aluminum, you can reduce the number of errors you make by learning  to set up your welder using proper gasses, wire feeds, and electrodes and using correct preparation of your work. Plus getting  advice from tutorials and more experienced welders. In time, you will feel as confident welding aluminum as you do steel.

Mild steel is the most commonly used of all metals and would be what you would purchase from your local merchant for your construction projects. This includes profiles such as thin sheet metal,  tubing, pipe, angle iron, square and round hollow sections and flat and round bar.

The difference between  pipe and tubing is generally the wall thickness and the methods of manufacture. Pipe is made in thickness of around 1/8″ up to 1/4″ for general work and in heavy industry pipes have even much thicker walls depending on the application.

Welding mild steel pipe is best carried out using a Mig welder or by using arc welding or stick welding. In cases where pipe work is a line for fluids the butt welds would generally need to be of xray quality and have no imperfections. This type of weld would also be performed by using the Tig process especially for smaller pipes and using stainless steel pipe.

Tubing is a lighter construction and is used for furniture making and light structural work, and range up to 1/8″ in wall thicknesses. Welding this type of material is best done using a Mig welder as they can be turned down to lower power settings, although arc welding can be used it requires more skill from the operator to avoid burning through the tube wall.

For general purpose welding a Mig welder is the most versatile machine to use, they can be used for both metals and aluminum provided you use the appropriate wire to suit the job. A machine of around 250 amps is all that would be required in a small workshop or for home use. While learning how to weld aluminum is more difficult to do than how to weld steel both can be accomplished by anyone with a little practice and guidance.

For more information on how to weld metal and an excellent welding manual check out our book review

While this is fine for some projects to take the risk of not knowing how to put down a strong weld, choosing the incorrect materials and welding process can be a recipe for disaster, especially when safety or personal harm is involved. You won’t want your new chopper frame to snap because of a cold lap weld!

Take the time to do some study and get it right, in the welding manual e-book welding secrets revealed you can learn:

• The correct welding procedures, techniques and instructions
• Tig and Mig welding tips
• How to identify metals and the uses of
• Welding safety, theory and applications.
• Weld preparation , joint preparation and design  
• Which gas, rods and wire to use
• How to set up your Mig, Tig, and Arc welders
• Gas Cutting, and  gas welding tips

How to weld Aluminum

Learning how to weld aluminum can be quite a challenge due to the oxide coating and lower melting point .
Aluminum can be frustrating to weld as there is no real visible evidence of melting when heat is applied, especially when gas and Tig welding. By following Aluminum welding instructions in how to set up your equipment and complete thorough joint preparation will help deliver great welds…

How to weld metal

Different metals and alloys require different welding methods, wires, gasses and machines, stainless steel, cast iron, aluminum, brass the list goes on. To really learn these other processes requires an extensive welding tutorial. However the majority of welding is with mild steel and only requires the basic equipment, learn how to weld metals

Welding Cast Iron

Learning how to weld cast iron is in general a difficult manual welding process. Cast iron welding is  mostly used for repair applications such as cast pumps, flanges and cast casings. For more information see how to weld cast iron