How To Setup A Tig Welder For Aluminum

Harrison Clayton December 18, 2023 3

TIG welding, also known as Gas Tungsten Arc Welding (GTAW), is a versatile process that can be used to weld a variety of materials, including aluminum. However, welding aluminum requires a slightly different setup than welding other materials, due to its unique properties.

The first step in setting up a TIG welder for aluminum is to ensure that you have the correct equipment. You will need a TIG welder with AC output, as this is necessary for welding aluminum. AC output allows the welder to alternate between positive and negative cycles, which helps to clean the oxide layer on the aluminum surface.

Next, you will need to select the appropriate filler rod for the job. When welding aluminum, it is important to use a filler rod that is compatible with the base metal. Typically, the filler rod should be made from the same alloy as the material being welded. This will help to ensure a strong, durable weld.

Once you have the correct equipment and filler rod, it is time to set up the TIG welder. Start by selecting the appropriate amperage for your project. For thinner aluminum materials, you will typically need a lower amperage setting, while thicker materials will require a higher amperage. It is important to strike a balance between too much heat, which can cause the material to warp, and too little heat, which can result in a weak weld.

Tig Welder Setup: Aluminum Welding Tips

When it comes to welding aluminum, proper setup of your TIG welder is crucial for achieving high-quality results. Aluminum poses some unique challenges compared to other metals, so it’s important to follow these tips to ensure a successful welding process.

Cleanliness is Key: Aluminum is highly sensitive to surface contaminants. Before starting the welding process, make sure to clean the aluminum surface thoroughly. Use a wire brush or a dedicated aluminum cleaner to remove any dirt, grease, or oxides that may be present.

Be Mindful of Base Metal Thickness: Aluminum conducts heat much more efficiently than other metals, meaning that thin sections of aluminum can quickly become overheated. Adjust your welder’s amperage and heat input accordingly to prevent distortion or burning through the metal.

Use the Right Electrode: For welding aluminum, it’s best to use a pure tungsten electrode. While alloys like thoriated tungsten can be used, they may contaminate the weld with undesirable elements. Ensure that the electrode is sharp and in good condition for optimal performance.

Select the Proper Shielding Gas: Argon is the most commonly used shielding gas for aluminum welding. Its inert properties help to protect the weld puddle from atmospheric contamination. Ensure that your gas flow rate is set correctly to provide adequate shielding.

Pulse welding: Pulse welding is a technique that can be beneficial for aluminum welding. It allows for better control of heat input and reduces the risk of warping or overheating the base metal. Experiment with pulse settings on your TIG welder to find the optimal parameters for your aluminum welding project.

Torch Angle and Travel Speed: When welding aluminum, it’s important to maintain a proper torch angle and consistent travel speed. A slight push angle and a steady travel speed can help to achieve good penetration and prevent excess heat buildup. Practice and experimentation are key to finding the right technique for your specific project.

Consider Filler Metal Selection: Choosing the right filler metal is essential for achieving strong and durable aluminum welds. ER4043 and ER5356 are commonly used aluminum filler metals and offer good weldability and tensile strength. Consult with your welding supplier to determine the most suitable filler metal for your specific application.

Preheat when necessary: In some cases, preheating the aluminum base metal can be beneficial, especially for thicker sections or when welding dissimilar metals. Preheating helps to minimize thermal stress, improve weldability, and reduce the risk of cracking or distortion.

Practice and Patience: Welding aluminum requires practice and patience. It may take time to master the techniques and settings needed for successful aluminum welding. Take the time to experiment, test welds, and make adjustments as needed to achieve the desired results.

Tig Welder Selection

When it comes to welding aluminum with a TIG welder, it’s essential to choose the right welder for the job. There are a few key factors to consider when selecting a TIG welder for aluminum welding:

Amperage Range: Ensure that the TIG welder you select has an amperage range suitable for aluminum welding. Aluminum requires higher amperage compared to other metals, so choosing a welder with a high amperage range will allow you to weld thicker aluminum materials.
AC/DC Capability: TIG welders with AC/DC capability are ideal for aluminum welding. Aluminum is best welded using alternating current (AC), as it helps in cleaning the surface oxides that form during the welding process. DC-only TIG welders can also be used for aluminum welding, but they won’t provide the same level of cleaning action as AC/DC welders.
Duty Cycle: Consider the duty cycle of the TIG welder. The duty cycle indicates the amount of time a welder can operate in a given time period without overheating. Aluminum welding requires longer welding times compared to other metals, so choose a TIG welder with a high-duty cycle to ensure uninterrupted welding.
Pulse Function: A pulse function in a TIG welder can be beneficial for aluminum welding. The pulse function allows you to alternate between high and low amperage levels, which helps control heat input and reduces the chances of burn-through on thin aluminum materials.
Gas Flow Control: Look for a TIG welder that offers gas flow control. Aluminum welding requires the use of shielding gas, usually pure argon or a mixture with helium. Having the ability to control the gas flow will ensure proper shielding and minimize contamination.
Foot Pedal Control: Having foot pedal control on your TIG welder can greatly improve your weld quality. Foot pedal control allows you to adjust the amperage while welding, providing more precision and control over the welding process.

By considering these factors when selecting a TIG welder for aluminum welding, you can ensure that you have the right equipment to achieve high-quality results. Make sure to do your research and choose a reputable brand known for producing reliable TIG welders.

Gas Selection for Aluminum Welding

When setting up a TIG welder for aluminum welding, choosing the right gas is crucial for achieving high-quality welds. Generally, the gas used for aluminum welding is pure argon or a mixture of argon with a small percentage of helium. The choice of gas depends on the thickness of the aluminum and the desired weld characteristics.

Pure argon is the most commonly used gas for aluminum welding. It provides good penetration and arc stability, making it suitable for thin to medium thickness aluminum. Argon is also less expensive compared to helium, making it a cost-effective option.

For thicker aluminum or when deeper penetration is required, a mixture of argon and helium is recommended. Helium increases the heat input, allowing for faster travel speeds and better penetration. A mix of 75% argon and 25% helium is commonly used for thicker aluminum sections.

Benefits of Using Argon for Aluminum Welding

Using argon gas for aluminum welding offers several benefits:

Improved weld quality: Argon helps produce clean, high-quality welds with reduced porosity and improved fusion.
Easy arc initiation: Argon provides a stable and smooth arc, making it easier to start and control the weld.
Wider process range: Argon can be used for a variety of aluminum thicknesses, making it versatile for different welding applications.
Cost-effective: Argon is generally less expensive than helium, making it a more budget-friendly option for aluminum welding.

Tips for Gas Selection

When selecting the gas for aluminum welding, keep the following tips in mind:

Check the manufacturer’s recommendations: Refer to the welding machine manufacturer’s guidelines or the welding filler material specifications for recommended gas choices.
Consider the thickness of the aluminum: Thicker aluminum may require a mixture of argon and helium to achieve adequate penetration.
Experiment and adjust: Depending on the specific welding application and desired results, experiment with different gas mixtures and settings to find the optimal combination.
Consult with professionals: If you are unsure about the gas selection or need expert advice, consult with welding professionals or suppliers for guidance.

Proper Amperage Setting

Setting the proper amperage is crucial for achieving successful TIG welding on aluminum. The correct amperage will depend on various factors, including the thickness of the aluminum, joint configuration, and welding technique. It is important to find the right balance of heat input to ensure proper fusion and minimize the risk of burn-through or incomplete penetration.

1. Base Amperage

Start by setting the base amperage, which is the amperage you will use for the majority of your weld. As a general rule of thumb, start with a base amperage of about 1 amp for every 0.001 inch of aluminum thickness. For example, if you are welding 1/8-inch thick aluminum, set the base amperage to around 125 amps.

2. Adjustments

After setting the base amperage, you may need to make slight adjustments depending on the specific welding situation. For thicker aluminum, you might need to increase the amperage slightly to ensure sufficient heat penetration. On the other hand, when welding thinner aluminum, you may need to decrease the amperage to avoid burn-through.

3. Polarity

Make sure to set the correct polarity for TIG welding aluminum. For DC TIG welding, use straight polarity (DC electrode negative) on the electrode and reverse polarity (DC electrode positive) on the workpiece. For AC TIG welding, the machine will automatically switch the polarity as needed.

4. Fine-Tuning

Once you have set the base amperage and polarity, it is a good practice to fine-tune the settings as you weld. Monitor the weld bead and adjust the amperage as needed to maintain a consistent, smooth bead profile. Keep in mind that different welding techniques, such as pulse or continuous current, may require different amperage settings.

Conclusion

Setting the proper amperage is crucial for successful TIG welding on aluminum. Starting with the correct base amperage and making adjustments based on the specific welding situation will ensure proper fusion and minimize the risk of defects. Remember to always refer to the manufacturer’s recommendations and guidance for your specific TIG welding machine.

Preparing and Cleaning Aluminum

Before you begin welding aluminum with a TIG welder, it is important to properly prepare and clean the aluminum surface. This will help ensure a successful weld and prevent any contamination that could weaken the joint.

Step 1: Remove any existing coatings or residues

Start by removing any existing coatings or residues from the aluminum surface. Use a chemical cleaner or solvent specifically designed for aluminum to strip away any paint, grease, or adhesive. This will help create a clean surface for welding.

Step 2: Remove any surface oxides

Aluminum tends to form a thin oxide layer on its surface, which can prevent proper welding. To remove this layer, use a stainless steel wire brush or a dedicated aluminum brush to lightly scrub the surface. This will help remove any oxides and provide a clean base for welding.

Step 3: Use a degreaser to remove oils

Even if the aluminum appears clean, it is important to use a degreaser to remove any remaining oils or contaminants. Apply the degreaser to a clean cloth or rag and wipe down the surface of the aluminum thoroughly. This will ensure that no oils are present that could cause contamination during welding.

Step 4: Avoid touching the cleaned surface

Once the aluminum is cleaned, it is crucial to avoid touching the prepared surface with bare hands. The oils and contaminants from your skin can easily transfer onto the aluminum, leading to contamination during welding. It is recommended to wear gloves or use clean, lint-free gloves when handling the cleaned aluminum.

Step 5: Store the aluminum in a clean environment

After preparing and cleaning the aluminum, it is important to store it in a clean environment until it is ready to be welded. This will prevent any contamination from occurring during the storage process.

By properly preparing and cleaning the aluminum surface, you can ensure a successful and high-quality weld when using a TIG welder. Follow these steps to create a clean base for welding and avoid any potential issues that could compromise the strength and integrity of the weld joint.

Electrode and Filler Wire Selection

Choosing the right electrode and filler wire is crucial for achieving high-quality TIG welding results on aluminum. Different types of electrode materials and filler wires offer varying levels of performance and suitability for different applications.

Electrode Selection:

When it comes to TIG welding aluminum, tungsten electrodes are the most commonly used. Thoriated tungsten electrodes (with 2% thorium) are ideal for welding aluminum due to their high resistance to heat and their ability to produce a stable arc. However, thoriated tungsten electrodes are radioactive and should be handled with caution. Alternatively, lanthanated tungsten electrodes offer similar performance to thoriated ones but are non-radioactive, making them a safer option.

The thickness of the aluminum being welded should also be considered when selecting the electrode diameter. A rule of thumb is to choose an electrode diameter that is equal to or slightly larger than the thickness of the aluminum. For example, for welding 1/8 inch thick aluminum, a 1/8 inch or 3/32 inch diameter electrode may be used.

Filler Wire Selection:

The choice of filler wire for aluminum TIG welding is critical in ensuring proper fusion and strength of the weld. The most commonly used filler wires for aluminum are ER4043 and ER5356. ER4043 filler wire is suitable for welding aluminum alloys that have a silicon content of less than 7%, while ER5356 filler wire is recommended for welding aluminum alloys with higher silicon content.

It is important to match the filler wire alloy with the base metal alloy to achieve optimal results. Additionally, the diameter of the filler wire should be selected based on the thickness of the material being welded. Thinner materials may require a smaller filler wire diameter, while thicker materials may require a larger diameter.

Proper electrode and filler wire selection is essential for achieving strong, high-quality welds on aluminum. By considering the specific requirements of the application and the properties of the base metal, welders can make informed decisions that result in successful TIG welding of aluminum.

Questions and answers

What is the best gas to use when welding aluminum?

The best gas to use when welding aluminum is pure argon. This inert gas helps to protect the weld from oxidation and produces a clean and smooth weld.

What type of tungsten electrode should I use for aluminum welding?

For aluminum welding, it is recommended to use a pure tungsten electrode. This type of electrode creates a stable arc and produces high-quality welds.

What should be the recommended amperage settings for aluminum welding?

The recommended amperage settings for aluminum welding depend on the thickness of the material. As a general guideline, you can start with an amperage of 1 amp per 0.001 inch of material thickness. However, it is important to make adjustments based on the specific requirements of the weld joint.

Is it necessary to use a foot pedal to control amperage when welding aluminum?

While it is not necessary to use a foot pedal to control amperage when welding aluminum, it can be a beneficial tool. A foot pedal allows for precise control of the heat input, which is important when welding aluminum to avoid burning through the material.

Harrison Clayton

Meet Harrison Clayton, a distinguished author and home remodeling enthusiast whose expertise in the realm of renovation is second to none. With a passion for transforming houses into inviting homes, Harrison's writing at https://thehuts-eastbourne.co.uk/ brings a breath of fresh inspiration to the world of home improvement. Whether you're looking to revamp a small corner of your abode or embark on a complete home transformation, Harrison's articles provide the essential expertise and creative flair to turn your visions into reality. So, dive into the captivating world of home remodeling with Harrison Clayton and unlock the full potential of your living space with every word he writes.