Best Welder for Aluminum (MIG/TIG)

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Hypertherm Powermax 65 25ft Hand Torch
Hypertherm Powermax 65 25ft Hand Torch #083270
$3,075.00
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Product Number: 083270
Hypertherm Powermax 30xp Plasma System
Hypertherm Powermax 30 XP Plasma Cutter #088079
$1,620.00
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Product Number: 088079
Powermax 125 Plasma Cutter
Hypertherm Powermax 125 Plasma Cutter #059536
$7,900.00
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Product Number: 059536
Thermal Dynamics Cutmaster 82 230V Plasma System
Thermal Dynamics Cutmaster 82 230V Plasma System Part #1-1130-1
$2,949.00
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Product Number: 1-1130-1
Thermal Dynamics Cutmaster 102 230V Plasma Cutting System
Thermal Dynamics Cutmaster 102 Plasma Cutter #1-1330-1
$3,749.00
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Product Number: 1-1330-1
Hypertherm Powermax 30 Air 120-240 V CSA with Building America decal
Hypertherm Powermax 30 Air 120-240 V CSA with Building America decal #...
$1,980.00
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Product Number: 088096
Thermal Dynamics Cutmaster 82, 80 Amp, SL60, 50 ft Leads, 208-230V, 1Ph
Thermal Dynamics Cutmaster 82 Plasma System, 80 Amp, SL60, 75 Deg Head...
$3,099.00
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Product Number: 1-1131-1
Cutmaster 82, 80 Amp, SL60, 50 ft Leads, 460V, 3Ph
Cutmaster 82 Plasma System, 80 Amp, SL60, 75 Deg Head, 50 ft Leads, 46...
$3,099.00
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Product Number: 1-1131-2
Cutmaster 82, 80 Amp, SL60, 20 ft Leads, 600V, 3Ph
Cutmaster 82 Plasma System, 80 Amp, SL60, 75 Deg Head, 20 ft Leads, 60...
$2,949.00
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Product Number: 1-1130-5
Victor Cutmaster 82 Plasma System, 80 Amp, SL60, 75° Head, 50 ft Leads
Victor Cutmaster 82 Plasma System, 80 Amp, SL60, 75 Deg Head, 50 ft Le...
$3,099.00
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Product Number: 1-1131-5
Thermal Dynamics Cutmaster 102, 100 Amp, SL100, 50 ft Leads, 208-230V, 1Ph
Cutmaster 102 Plasma System, 100 Amp, SL100, 75 Deg Head, 50 ft Leads,...
$3,899.00
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Product Number: 1-1331-1
Cutmaster 102, 100 Amp, SL100, 20 ft Leads, 460V, 3Ph
Cutmaster 102 Plasma System #1-1330-2
$3,749.00
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Product Number: 1-1330-2
Cutmaster 102, 100 Amp, SL100, 50 ft Leads, 460V, 3Ph
Cutmaster 102 Plasma System, 100 Amp, SL100, 75 Deg Head, 50 ft Leads,...
$3,899.00
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Product Number: 1-1331-2
Cutmaster 102, 100 Amp, SL100, 20 ft Leads, 600V, 3Ph
Cutmaster 102 Plasma System, 100 Amp, SL100, 75 Deg Head, 20 ft Leads,...
$3,749.00
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Product Number: 1-1330-5
Cutmaster 102, 100 Amp, SL100, 50 ft Leads, 600V, 3Ph
Cutmaster 102 Plasma System, 100 Amp, SL100, 75 Deg Head, 50 ft Leads,...
$3,899.00
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Product Number: 1-1331-5
Cutmaster 152, 120 Amp, SL100, 50 ft Leads, 208-230V, 1Ph
Cutmaster 152 Plasma System, 120 Amp, SL100, 75 Deg Head, 50 ft Leads,...
$4,899.00
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Product Number: 1-1731-1
Cutmaster 152, 120 Amp, SL100, 20 ft Leads, 460V, 3Ph
Cutmaster 152 Plasma System, 120 Amp, SL100, 75 Deg Head, 20 ft Leads,...
$4,749.00
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Product Number: 1-1730-2
Cutmaster 152, 120 Amp, SL100, 50 ft Leads, 460V, 3Ph
Thermal Dynamics Cutmaster 152 Plasma System, 120 Amp, SL100, 75 Deg H...
$4,899.00
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Product Number: 1-1731-2
Cutmaster 152, 120 Amp, SL100, 20 ft Leads, 600V, 3Ph
Cutmaster 152 Plasma System, 120 Amp, SL100, 75 Deg Head, 20 ft Leads,...
$4,749.00
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Product Number: 1-1730-5
Cutmaster 152, 120 Amp, SL100, 50 ft Leads, 600V, 3Ph
Cutmaster 152 Plasma System, 120 Amp, SL100, 75 Deg Head, 50 ft Leads,...
$4,899.00
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Product Number: 1-1731-5
Cutmaster 152, 120 Amp, SL100, 20 ft Leads, 208-230V, 1Ph
Cutmaster 152 Plasma System, 120 Amp, SL100, 75 Deg Head, 20 ft Leads,...
$4,749.00
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Product Number: 1-1730-1
Hypertherm Powermax 105
Hypertherm Powermax 105 Plasma Cutter #059374
$5,999.00
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Product Number: 059374
Hypertherm Powermax 65 25 ft  Hand Torch +180° Machine Torch + CPC
Hypertherm Powermax 65 Plasma Torch (200-600 V CSA) 25 ft: 75° Hand He...
$3,625.00
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Product Number: 083300
THERMAL DYNAMICS Cutmaster A120 1-1735-1
THERMAL DYNAMICS Cutmaster A120 1-1735-1
$4,722.80
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Product Number: 1-1735-1
Hypertherm Powermax 45 XP Hand System #088112
Hypertherm Powermax 45 XP Hand System w/o CPC - 20' Leads #088112
$2,240.00
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Product Number: 088112
Hypertherm Powermax 45 XP Hand System w/ CPC - 20' Leads
Hypertherm Powermax 45 XP Hand System w/ CPC - 20' Leads #088113
$2,360.00
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Product Number: 088113
Hypertherm Powermax 45 XP Hand System w/o CPC - 50' Leads
Hypertherm Powermax 45 XP #088114 Hand System w/o CPC - 50' Leads
$2,400.00
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Product Number: 088114
Hypertherm Powermax 45 XP Hand System w/ CPC - 50' Leads
Hypertherm Powermax 45 XP Hand System #088115 w/ CPC - 50' Leads
$2,525.00
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Product Number: 088115
Hypertherm Powermax 45 XP Hand System w/ CPC 75 & 15 deg Torches - 20'
Hypertherm Powermax 45 XP #088124 Hand System w/ CPC 75 & 15 deg Torch...
$2,410.00
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Product Number: 088124
Hypertherm Powermax45 XP Machine System CPC 25' w/ Remote On/Off
Hypertherm Powermax45 XP #088116 Machine System CPC 25' w/ Remote On/O...
$2,650.00
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Product Number: 088116
Hypertherm Powermax45 XP Machine System CPC 35' w/ Remote On/Off
Hypertherm Powermax45 XP #088117 Machine System CPC: 35' w/ Remote On/...
$2,700.00
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Product Number: 088117
Hypertherm Powermax45 XP Machine System CPC 50' w/ Remote On/Off
Hypertherm Powermax45 XP #088118 Machine System CPC 50' w/ Remote On/O...
$2,775.00
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Product Number: 088118
Hypertherm Powermax 45 XP Machine System CPC 25' Leads
Hypertherm Powermax 45 XP #088121 Machine System CPC 25' Leads
$2,460.00
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Product Number: 088121
Hypertherm Powermax 45 XP Machine System CPC 50' Leads
Hypertherm Powermax 45 XP #088122: Machine System CPC 50' Leads
$2,575.00
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Product Number: 088122
Hypertherm Powermax 45 XP Machine System CPC 180M & 75H Torches 25' Leads
Hypertherm Powermax 45 XP #088123 Machine System CPC 180M & 75H Torche...
$2,975.00
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Product Number: 088123
Miller Spectrum 875 Plasma Cutter with XT60 Torch, 20ft OR 50ft Cable Miller Spectrum 875 Plasma Cutter with XT60 Torch, 20ft OR 50ft Cable
Miller Spectrum 875 Plasma Cutter with XT60 Torch, 20ft OR 50ft Cable
$3,245.00
$4,096.00* You Save $851.00
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Product Number: 907583
Miller Spectrum 875 Auto-Line XT60 Hand-Held Torch Miller Spectrum 875 Auto-Line XT60 Hand-Held Torch
Miller Spectrum 875 Auto-Line XT60 Hand-Held Torch with 20ft Cable #90...
$3,495.00
$4,430.00* You Save $935.00
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Product Number: 907584
Hobart AirForce™ 12ci Plasma Cutter #500564
Hobart AirForce™ 12ci Plasma Cutter #500564
$872.05
$1,135.00* You Save $262.95
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Product Number: 500564
Thermal Dynamics Cutmaster 60i #1-5631-1 w/ 50' Torch
Thermal Dynamics Cutmaster 60i #1-5631-1 w/ 50' Torch
$2,649.00
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Product Number: 1-5631-1X
Thermal Dynamics Cutmaster 60i #1-5630-1 20' Torch
Thermal Dynamics Cutmaster 60i #1-5630-1X 20' Torch
$2,499.00
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Product Number: 1-5630-1X
Hypertherm 600 V Powermax 125 Plasma Cutter #059551
Hypertherm 600V Powermax 125 Plasma Cutter #059551
$8,750.00
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Product Number: 059551
Thermal Dynamics Cutmaster 60i #3-5630-1X (Power Supply Only)
Thermal Dynamics Cutmaster 60i #3-5630-1X (Power Supply Only)
$3,092.00
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Product Number: 3-5630-1X
Thermal Dynamics Cutmaster 60i 3-Phase Plasma Cutter 20' Torch #1-5630-2
Thermal Dynamics Cutmaster 60i 3-Phase Plasma Cutter #1-5630-2X
$2,499.00
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Product Number: 1-5630-2X
Thermal Dynamics® Cutmaster® 60i 3-Phase Plasma Cutter with 50 Foot Torch #1-5631-2
Thermal Dynamics® Cutmaster® 60i 3-Phase Plasma Cutter with 50-Foot To...
$2,649.00
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Product Number: 1-5631-2
Hypertherm PowerMax45 XP 3-Phase Hand System W/O CPC - 20' Leads #088126
Hypertherm PowerMax45 XP 3-Phase Hand System W/O CPC - 20' Leads #0881...
$2,480.00
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Product Number: 088126
Miller LiveArc Welding Performance Management System Miller LiveArc Welding Performance Management System
Miller LiveArc Welding Performance Management System #907714001
$57,360.95
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Product Number: 907714001
Thermal Dynamics Cutmaster 58, 20 ft. SL60QD, 208-230 VAC
Thermal Dynamics Cutmaster 58, 20 ft. SL60QD, 208-230 VAC 1-5830-1
$1,999.00
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Product Number: 1-5830-1
Thermal Dynamics Cutmaster 58, 20 ft. Lead W/SL60QD Torch
Thermal Dynamics Cutmaster 58, 20 ft. Lead W/SL60QD Torch, 460 VAC #1-...
$1,999.00
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Product Number: 1-5830-2
Thermal Dynamics Cutmaster 58, 20 ft. Lead W/SL60QD Torch, 600 VAC
Thermal Dynamics Cutmaster 58, 20 ft. Lead W/SL60QD Torch, 600 VAC #1-...
$1,999.00
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Product Number: 1-5830-5
Thermal Dynamics Cutmaster 58, 50 ft. Lead W/SL60QD Torch, 208-230 VAC
Thermal Dynamics Cutmaster 58, 50 ft. Lead W/SL60QD Torch, 208-230 VAC...
$2,149.00
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Product Number: 1-5831-1
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Best Welder For Aluminum

In its pure form, aluminum is a relatively soft metal with good ductility and high resistance to corrosion. Alloys are typically added to give it more structural rigidity, so most aluminum welding is done on aluminum alloys. Even with the added strength alloys give aluminum, the high thermal conductivity and a low melting point of aluminum alloys make it prone to distortion and burn-through during welding. Although aluminum can be joined by brazing and soldering, these have very limited applications. For welding aluminum, the most commonly used machines are MIG and TIG welders.

What type of welding machine do you need to weld aluminum?

Your best options boil down to MIG or TIG welders. Here’s a quick look at each:

TIG Welders for Aluminum

TIG welding is the preferred process for working with aluminum—especially thin aluminum. The high thermal conductivity and a low melting point of aluminum can lead to warping and burn-through if heat input isn’t carefully controlled. TIG welding aluminum is ideally suited for this. The welds they produce are not only strong, they also look great. It takes practice to get the consistent “stacked dimes” look on your welds, but with the right waveform setting, the right consumables, and good control of heat input it can be done. Having the right equipment is the first step, and Welders Supply can help with that.

Check out our welders, including:

 

Benefits of TIG welders for aluminum

  •         Strong, durable welds
  •         Provide optimal control of heat input
  •         Best looking weld beads of any welding process

 

Shop all TIG welders at Welders Supply

TIG Welding Aluminum (Best Welder for sale)

MIG welders for aluminum

There are many machines capable of MIG welding aluminum, and most also weld mild and stainless steel. However, welding aluminum with a MIG welder is trickier than welding steel because it requires more heat, and aluminum (especially thin gauge aluminum) is particularly susceptible to warpage and burn-through. For anything thinner than 14 gauge aluminum, you need a TIG welder. Even with thicker gauge aluminum, you need to move the gun quickly and develop a feel for when the weld puddle is getting too hot. MIG welders will work fine on heavy gauge aluminum, but for precision work on thinner aluminum, a TIG welder is recommended.

Benefits of MIG welders for aluminum

  •         MIG welding is about the easiest welding process to learn
  •         Works well for thicker gauge aluminum (16 gauge and up)
  •         Can weld faster with MIG process than with TIG
  •         Generally less expensive than TIG machines

 

Shop all MIG welders at Welders Supply

 

What About Stick Welders for Aluminum?

Yes, a stick welder can be used to weld aluminum, but even when used for welding thicker gauge aluminum it is a poor substitute for MIG or TIG welding. Not only is it difficult to control the heat input, but any welding process that uses a flux is prone to problems. Besides the difficulty of keeping the flux rods and wires free of atmospheric contamination, the welds often have such high porosity that they fail. Verdict: not recommended!

Not Sure Which Type of Welding Machine to Buy?

If you’re on the fence about which type of welder will work best for you, or have questions about a specific machine, free to email or call us. We can help you choose a welding machine that meets your needs and your budget.

 

Check out the full selection of Welders chosen by the type of welding material at Welders Supply Company.

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