How to Tig Weld Aluminum? Briefly Explanation of Welding

However, aluminum welding presents other challenges, from modeling the heat into dealing with the oxide layer. Gas Tungsten Arc Welding (GTAW) has been regarded as the leading aluminum welding method. Because due to the high welding integrity and good appearance of the process, it provides how-to Tig weld aluminum.

Aluminum-producing products can increase health, reduce weight, and provide more excellent reliability at colder temperatures. That aluminum product makes the material more convenient for use, such as truck and tile manufacturing, cryogenic pipes, and boat parts.

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Operation Process of How to Tig Weld Aluminum

This method is more complicated than any other method. This method requires a two-hand operation to handle. One hand is busy handling the welding torch, and the other hand is active in feed to filler metal. A welder has to maintain the distance between the electrode and the workpiece to avoid contact.
A high-quality generator is required to provide electricity spark to the welding arc. One more thing is to create a circle path to create a pool of welding. It is more important to contain a separate distance between the electrode and workpiece to avoid any problem.

Basic Principles of GTAW Aluminum

First of all, users must remember some Basic Rules Before Using Gas Tungsten Arc Weld Aluminum. Some of the basic principles are as follows:

  • Firstly, one most important thing to keep in mind that all parts of metal should be clean and clear. There will be no dirt or rust on the metal parts. If necessary, clean the welding material with any type of bush, grinder, so that metals should be in great shape.
  • The welder should choose the correct shielding gas and electrodes for the welding process. These two things of welding are very important. Users must choose the electrode size wisely and must accept the accurate electrode.
  • Users are sure to select the correct shielding gas for welding because shielding gas has the most important impact on the welding. They must wisely prepare the electrode and the point. 
  • The other basic principle is that your work should be properly ventilated and clean. The welding material is also clean and clear.
  • Use the specific chart of ampere and voltage of material, which shows the accurate voltage and ampere to welders.
  • Make sure that the working connections must be accurate and good enough. For welding, all connections must be in the right conditions.
  • Two extra chains are used in this welding cart to help you with the Tig welders’ management. These chains come in handy for holding the gas tanks used for Tig welding.
  • Two extra trays have been provided. These trays help you keep the accessories and other equipment that you might need while working.
  • This method of welding’s size is maintained by keeping the usual fitting of welders in mind.

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Set AC Output Frequency

Another factor that simplifies weld placement is the frequency of AC discharge. This can also be set and repaired in modern welding power sources. The AC output frequency should not be confused with the start of a high-frequency arc, which only comes when the arc starts.

The output frequency indicates how many times a second, the power source changes the unity. The old GTAW power source is 60 hertz, determined by the input power, but the modern equipment has factory equipment that produces a 120-Hz frequency.

Stable Frequency

As the AC frequency rises, the arc becomes more stable. These results in a rigid, thin arc column that provides the vertical control that allows you to weld easily into tight spaces and bend well without arc rotation.

Reducing the AC output frequency to 80 or 90 Hz provides a wider arc cone, which can be useful when heating an integrated outer ring, and it’s telling that how to Tig weld aluminum.

Use a 150 to 250 Hz output frequency for soft objects that require direct placement of the weld to prevent large-area warming or central heating. For thick welding applications, a low AC frequency of 80 to 120 Hz is well suited for resources 3⁄8 in. It is also great and will help you achieve a wider weld bead profile.

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What is Welding?

Welding is the process by which you can join the metals or something like this by using the healing process etc. In the welding process, you can join the metal things by using the heat, and from this, base metal cannot be melt. Tig Welding (Tungsten Inert Gas) is the finest process by which you can join the metal and putting some tungsten electrode between them.

This welding technique is becoming more popular with time because of the ease they provide. Even the lightweight welders need to be dragged to places, which will increase the risk of accidents.

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Methods of Welding

There are different methods of welding, which are as follows:

  • Shielded Metal Arc Welding Process.
  • Gas Tungsten Arc Welding Process.
  • Gas Metal Arc Welding Process.
  • Flux Cored Arc Welding Process.
  • Submerged Arc Welding Process.
  • Electroslag Welding Process.

These are the different welding processes, while the central and important method is the Gas Tungsten Arc Welding process, also known as Tig Welding.


Gas Tungsten Arc Welding (GTAW) is used on thin metals that can be weld easily. This method applies to especially thin metals like stainless steel. It can weld the soft, thin sections of metals like Aluminum, Magnesium, etc. This type of welding demands higher quality welder with a strong command of the machine.

Finding high-quality welds and getting a timed look where aluminum welding with GTAW takes practice and skill. It also helps to follow some of the best practices for how to Tig weld aluminum.

Gas Tungsten Arc Welding

This process is also known as Tungsten Inert Gas, and it is done by manual operation. It is the finest welding process in which no consumable electrode is used with some separate filler type material, an inert gas mixture is also used. Master can only do this method.

Tig welding is also known as Gas Tungsten Arc Welding (GTAW), and it is the process of welding metals with the help of an arc. The help of shielding gas uses this process. Welding has many types, and Tig Welding is one of the types.

It can be applied to all metals which can be weld. This method is only suitable for thin metals like stainless steel etc. A high-quality arc is also necessary for this welding process.

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Importance of Gas Tungsten Arc Welding

Gas Tungsten Arc Welding (GTAW) is used on thin metals that can be weld easily. This method is especially applicable to very thin metals like stainless steel. It can weld the soft, thin sections of metals like Aluminum, Magnesium, etc. This type of welding demands higher quality welder with a strong command of the machine.

It is also known as a two-handed technique because one hand is holding the torch, and others feed the filler material. It is furthermore a more complex technique as compared to other techniques of welding.

So this provides you with all the best features and enough strength to carry out your work. Furthermore, the carrying capacity is enough to manage heavy welders.

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Penetration Problem

Users can control when the filter metal is being added with Tungsten, and then they can prepare the filter and have the proper penetration. Users must remember that more control over this flexibility can add another layer and complexity for the operator compared to other processes such as GMAW.

Appropriate heat input is a critical feature of the successful installation of aluminum with GTAW. Because the aluminum material is so versatile in nature, the welding heat can be quickly removed. This feature of how to Tig weld aluminum needs to press the heat to prepare a welding puddle. However, this heat must be controlled to protect the fleece or burn.

Amperage and voltage have their welding heat, which means that the higher the arc voltage, the more energy will be absorbed into the component. Although heat with a long arc increases the arc voltage, it produces more heat and absorbs a larger area. This can create a fast-growing puddle. To prevent this, use short arc lengths to help get heat into the small space.

In addition to proper heat control, consider these tips for adding effects when lubricating aluminum with GTAW.

Adjust Balance Management

Another important step in making a good aluminum weld is to set the proper balance control. When heated to AC polarity, the weld has an electrode-negative (EN) cycle and half of the electrode cycle. EN is often seen as a hot component of the AC waveform, while the EP is where cleaning or removal of the oxide occurs.

In modern welding equipment, the balance control feature allows you to adjust the ratio between the two in response to what you see in the welded frame.

While older machines have a 50-50 average rating for EN and EP, most modern GTAW power sources have an average operating control of 75 to 25 percent of the EP. When black spots appear in the hole between floors – often referred to as “peppering” – your balance control is not well adjusted.

Overcoming Aluminum Challenges with GTAW

GTAW is indeed a slow and inexpensive process in high-performance applications. It has been the best choice for aluminum casting applications over the years. But manufacturing is not as important as better quality and appearance for telling how to Tig weld aluminum.

During the heating of the aluminum by the arc welding (GMAW) gas process, the filler metal is put into the bag as soon as the welder melts the gun. This “onset of cold” can lead to a lack of balance and poor posture.

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There are different characteristics of Gas Tungsten Arc Welding, which are going to be discussed here:

Non-Consumable Electrode

A welder uses the non-consumable electrode during the whole welding process. In this method of welding, you can join the metal things by using the heat, and from this, base metal cannot be melt.

It is a modest welding process in which no consumable electrode is used with some separate filler material, and inert gas mixture is also used.

Number of Gases Used

This method has a variety of gases used to join metals. You can use helium, argon gases to join the metals easily. With the help of these gases, you can weld a wide range of metals easily.

Applied on Thin Metals

It is only applied on thin metals like stainless steel and other thin materials. Users can use this process on thin materials and especially on stainless steel etc. This process does not apply to other than thin metals.

High-Quality Weld

From this process of welding, users can produce high-quality welds. They can weld quickly thin metals with the help of different equipment and different safety measures. So that users have no problem of getting injured.

Easy transportation

The different measurements of this welding method are kept very precise to enhance transportation. You will be able to transport TIG welder, AC welders, MIG welders, and plasma cutters. You will also get enough space to keep your tools and accessories safe.

Safety chains

Two safety chains are provided in this welding method that helps you to catch up on things that need extra support. For instance, a gas cylinder needed for this type of welding.

For all Thin Metals

This welding process can be used to join all types of thin quality metals very easily. Users can easily do high-quality welding with the help of GTAW. Helium and argon gases make so much good impact on the welding piece that there will be no slag on pieces.

Hence, with high-quality generators, users can easily generate actual electric current to do welding. Users can join different metals with the help of different techniques. Users can make the welds completely free of defects.

Filler Material       

Users can do welding with filler material and without filler material on demand. There is no any precautionary measure to do only filler material. So they can do both filler material do without filler material welding.

Extra control

This process provides users with extra control over the heating intensity and the filler material etc. Users can control the heat intensity, whether to apply maximum heat or minimum heat to metals.

Ideal for Fillet Welded Joints

This method of welding is ideal for fillet welded joints. Users can do fill small joints as well as easily. This type of welding keeps the welder busy filling small holes etc. They can join different small metals easily.

Root Passes

Gas Tungsten Arc Welding (GTAW) can also be used to join the root passes. Users can join root passes with the help of GTAW. This welding demands the cleanliness of the welder. Although, this is the most important part of the welding process because it fills, joins the root passes with ease.

Aluminum Alloys

Aluminum alloys are used for the How to Tig weld aluminum process. These alloys will give them a good shape and make the work easy. Many aluminum alloys are available in the market. But some aluminum alloys are best of best in performance.

Indeed, the most popular aluminum alloy the pure aluminum allows and the aluminum-magnesium allow. This allay is very important in Tig weld aluminum. Sometimes aluminum got damaged, and its repairing will be done from these alloys. Aluminum brazing is also used for the repairing of aluminum alloys.

Some aluminum alloys are very helpful in how to Tig weld aluminum. These are as follows:

  • 1xxx-99 percent pure aluminum alloy is most used.
  • 2xxx-copper-aluminum alloy.
  • 3xxx-magnese aluminum alloy.
  • 4xxx-silicon aluminum alloy.
  • 5xxx-magnesium-aluminum alloy.
  • 6xxx-silicon-magnesium and aluminum alloy.
  • 7xxx-zinc and aluminum alloys.

These aluminum alloys are very important in Tig weld aluminum. So make sure these aluminum alloys must be in good and perfect condition.

Alternating Current

When aluminum for TIG welding, alternating current (or “AC”) is almost used, then it tells the process of how to Tig weld aluminum. The current exchange has the effect of spitting on the surface, breaking down oxides that terminate the weld’s quality. However, TIG weld aluminum can have a direct current (also referred to as “DC”). In some cases, DC is a better choice for TIG weld aluminum. 

TIG welding aluminum with a straight current can be tricky, but these tactics can help you get it done.

  • Recognize the difference in current understanding and current TIG welding exchange.
  • Know when to use DC and when to use AC aluminum.
  • Use the right materials.
  • Assemble the correct electrode, rods, and protective gear.
  • Set DC Welding welder with reduced polarity.
  • Use a foot pedal or amperage hand control.
  • Get aluminum as clean as possible.
  • Practice before starting the weld.
  • Use proper procedures.
  • Know your exact limits now are not always the right choice for aluminum.
  • Combine AC and DC Welding to find the best combination.

Best of Both Worlds

For some projects, using AC and DC can be a winner. For very large stock, you may need to combine strategies to get the best result. To get the best procedure for how to Tig weld aluminum, use the following steps:

  • Lay the edges of the pieces together so that they fit together in a V shape.
  • Make root beads using real ones. This is the base of the weld that fills the bottom of the v channel. DC will provide deep penetration and a solid weld base.
  • Rub the weld clean to remove as much oxidation and impurities as possible.
  • Make a cap weld using alternating current. AC will disperse contaminants from the surface of the root weld and the edges of the joint. AC also makes it easy to find an attractive weld hit that looks like a smooth dimes stack.

The current variable is the TIG aluminum level of the TIG for a good reason. It handles aluminum surfaces well and makes beautiful welds look great. However, AC welding has its limitations. If you need deeper penetration into thick aluminum, guide the better current entry and provide a better weld. 

Advantage and Disadvantages of Tig Weld Aluminum

There are many advantages and disadvantages of Tig Weld Aluminum, which are as follows:


  • Filler Rod is necessary for some Tig welding techniques, but it is not important in the Tig weld aluminum.
  • There will be a Polarity of AC (Alternative Current) for magnesium and aluminum welding purposes.
  • Aluminum Tig weld can possess high-quality welding. It can give high-quality welding to users.
  • Aluminum Tig Welding can also be used in various metals. It can also be used on most metals, its varieties.
  • Like the normal Tig Welding, Aluminum Tig welding is also used on very thin metals. It is only applicable to thin metals.
  • From Aluminum Tig welding, users can easily do fusion welding. Users can easily do the fusion Tig welding from this.
  • There will be no damage or no type of slag done by the Aluminum Tig welding. Users can do welding quite efficiently and correctly.
  • Users can do their welding quite efficiently. It demands high efficiency from the users.


  • This Aluminum Tig welding is not appropriate for outdoor welding. It is entirely unsuitable for outdoor welding. Users have to do this welding for indoor purposes.
  • It has very low deposition rates, which are very unfit for welding. So Tig welding aluminum has low deposition rates for welding.
  • Tig weld aluminum requires a clean and clear base material, which is not necessary for the welding.
  • Tig weld aluminum is quite slow and as compared to other types of welding.


How to Tig weld aluminum has one of the major problems with this metal welding process? It welds only thin metal material of the flux, especially in fillet welds, where the bubble can be stuck to the back of the welding and raise the rust from the welding process. Hence other problems that have been resolved from the welding process tend to accumulate significantly.