TIG Welding Aluminum - How To Get Started

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TIG welding aluminum can prove very useful for a wide variety of tasks. One of which is to TIG weld aluminum. Here we tell you not only how to do that, but also how to get that stack of dimes look with your weld. First off, you, of course, ought to have a machine. You don't need the latest design - even old and well-functioning ones will be great. Whether it is an old Synrowave 300, or an old Hobart CyberTIG, any of them will serve the purpose well. If you don't have a machine already, you better borrow one, or get a new one for yourself. Here we tell you how to weld aluminum like you want to:

First check the TIG machine settings:

- Set the current polarity Alternating Current or A/C

- The amperage should be 1.5 amps per 1/1000 of inch of thickness (this is valid up to about 250 amps; above that the numbers are slightly different)

- The amperage and contactor buttons should be set to remote position

- If you are using a #7 cup, the argon/helium torch shielding gas should be set to around 15 cfh. Less than 15cfh if the cup is smaller.

The steps to get the stacks-of-dime look

- For a 1/8" aluminum, use a 4043 filler rod in 3/32 diameter. You rarely need a rod thicker than the metal being worked on.

- Extending the tip of the electrode 1/2" past the tip of the TIG torch cup, pre purge the gas by tapping the foot pedal.

- Touch the tungsten tip to the surface of the metal. You should be holding the torch like you hold a pencil. Put on your helmet, pull back the tip and start the arc.

- Now for that "stack of dimes" look. That is achieved by repeatedly adding the rod to the metal at evenly spaced intervals. That is, you add the rod at a point, move the tip 1/8th of an inch and then again drop the rod. You do this a number of times and you have the stacks of dime look in your job.

TIG welding aluminum sounds easier than it is to do and you will need practice to do this with a satisfactory quality. But it is far from impossible and you will be working like an expert in shorter time than it took you to learn to drive. Seeing as TIG welding aluminum is a very sought-after skill you should be able to make money off of your expertise relatively easily.