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Best Welder for Aluminum (MIG/TIG)

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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 600 V Powermax 125 Plasma Cutter #059551
Hypertherm 600V Powermax 125 Plasma Cutter #059551
$8,050.00
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Product Number: 059551
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...
$2,330.00
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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 60i
Thermal Dynamics Cutmaster 60i 3-5630-2X (Power Supply Only)
$2,113.25
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Product Number: 3-5630-2X
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 1-5...
$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 1-5...
$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
Thermal Dynamics Cutmaster 58 1-5831-2
Thermal Dynamics Cutmaster 58 1-5831-2, 50 ft. Lead W/SL60QD Torch
$2,149.00
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Product Number: 1-5831-2
Thermal Dynamics Cutmaster 58
Thermal Dynamics Cutmaster 58 1-5831-5, 50 ft. Lead W/SL60QD Torch, 60...
$2,149.00
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Product Number: 1-5831-5
AugmentedArc® Augmented Reality Welding System AugmentedArc® Augmented Reality Welding System
Miller AugmentedArc® Augmented Reality Welding System 951823
$27,993.75
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Product Number: 951823
Multimatic® 235 Multiprocess Welder w/ EZ-Latch™ Running Gear Multimatic® 235 Multiprocess Welder w/ EZ-Latch™ Running Gear
Multimatic® 235 Multiprocess Welder w/ EZ-Latch™ Running Gear 951846
$2,849.00
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Product Number: 951846
New Bobcat™ 200 Air Pak 907771 New Bobcat™ 200 Air Pak 907771
New Bobcat™ 200 Air Pak 907771 Enchanced Gas Model
$12,759.00
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Product Number: 907771
Hypertherm Powermax45 XP Machine System CPC/Serial 1/0 Cables 25'
Hypertherm Powermax45 XP #088119 Machine System: CPC/Serial 1/0 Cables...
$2,775.00
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Product Number: 088119
Miller Trailblazer® 325 (Kohler) EFI w/Battery Charge/Jump Start, Excel™ Power & Wireless Interface Control 907798005
Miller Trailblazer® 325 (Kohler) EFI w/Battery Charge/Jump Start, Exce...
$11,205.00
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Product Number: 907798005
Miller Trailblazer® 325 (Kohler) EFI w/ Excel Power 907798002
Miller Trailblazer® 325 (Kohler) EFI w/ Excel Power 907798002
$8,705.00
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Product Number: 907798002
Miller Trailblazer® 325 EFI w/GFCI, Excel™ Power & Wireless Interface Control 907798003
Miller Trailblazer® 325 EFI w/GFCI, Excel™ Power & Wireless Interface ...
$10,485.00
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Product Number: 907798003
BOBCAT 200 AIR PAK DIESEL BOBCAT 200 AIR PAK DIESEL
Miller Bobcat™ 200 Air Pak™ Diesel #907760
$17,214.00
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Product Number: 907760
BIG BLUE 400 PRO (CAT) BIG BLUE 400 PRO (CAT)
Miller Big Blue® 400 Pro (CAT) #907774
$18,140.00
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Product Number: 907774
BIG BLUE 400 PRO (CAT) W/ ARCRE BIG BLUE 400 PRO (CAT) W/ ARCRE
Miller Big Blue® 400 Pro Engine-Driven Welder #3907774001
$18,896.00
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Product Number: 907774001
PKG,ALUMAFEED 350 WELD SYS W/25 PKG,ALUMAFEED 350 WELD SYS W/25
Miller AlumaFeed 350 Mpa stationary pkg with 25ft. air-cooled XR-Aluma...
$12,737.00
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Product Number: 951834
PKG,ALUMAFEED 350 MIGRUNNER W/2 PKG,ALUMAFEED 350 MIGRUNNER W/2
Miller AlumaFeed 350 Migrunner with water-cooled XR-Pistol Pro 25ft. #...
$16,335.00
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Product Number: 951835
PKG,ALUMAFEED 350 WELD SYS W/25 PKG,ALUMAFEED 350 WELD SYS W/25
Miller Alumafeed 350 MPa Stationary package with 25ft. Pistol-Pro Air-...
$12,299.00
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Product Number: 951836
PKG,ALUMAFEED 350 MIGRUNNER W/2 PKG,ALUMAFEED 350 MIGRUNNER W/2
Miller AlumaFeed 350 MPa Migrunner with 25ft. Water-Cooled XR- AlumaPr...
$16,872.00
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Product Number: 951837
PKG,ALUMAFEED 450 MIGRUNNER W/2 PKG,ALUMAFEED 450 MIGRUNNER W/2
Miller AlumaFeed 450 MPa Migrunner with 25ft. XR Aluma-Pro Air-Cooled ...
$15,145.00
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Product Number: 951840
PKG,ALUMAFEED 350 MIGRUNNER W/3 PKG,ALUMAFEED 350 MIGRUNNER W/3
Miller AlumaFeed 350 MPa Migrunner with 25ft. XR Pistol-Pro-Pro Air-Co...
$14,357.00
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Product Number: 951841
PKG,ALUMAFEED 450 WELD SYS W/25 PKG,ALUMAFEED 450 WELD SYS W/25
Miller AlumaFeed 450 MPa Stationary Package with 25ft. XR Aluma-Pro Wa...
$14,715.00
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Product Number: 951842
SPECTRUM 875 60A 208/230 1PH 25 SPECTRUM 875 60A 208/230 1PH 25
Miller SPECTRUM 875 60A 208/230 1PH 25 907583002
$3,755.00
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Product Number: 907583002
SPECTRUM 875 AUTO-LINE 208-575 SPECTRUM 875 AUTO-LINE 208-575
Miller SPECTRUM 875 AUTO-LINE 208-575 907584002
$4,149.00
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Product Number: 907584002
SPECTRUM 875 AUTO-LINE 208-575 SPECTRUM 875 AUTO-LINE 208-575
Miller SPECTRUM 875 AUTO-LINE 208-575 907584004
$4,285.00
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Product Number: 907584004
RACK 6-PK XMT 350 CC/CV FIELDPR RACK 6-PK XMT 350 CC/CV FIELDPR
Miller XMT® 350 FieldPro™ 6-Pack Rack fused 460/575 V Tweco #907740
$46,579.00
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Product Number: 907740
RACK,6-PK XMT 350 FIELDPRO POLA RACK,6-PK XMT 350 FIELDPRO POLA
Miller XMT® 350 FieldPro™ with Polarity Reversing 6-Pack Rack fused 46...
$51,012.00
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Product Number: 907741
XR-A ALUMA-PRO 35FT.
Miller XR-Aluma-Pro™ 35 Ft. Air 301570
$3,119.00
$3,602.00* You Save $483.00
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Product Number: 301570
XR-W ALUMA-PRO 15FT.
Miller XR-Aluma-Pro™ 15 Ft. Water 301571
$3,019.00
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Product Number: 301571
XR-W ALUMA-PRO 25FT.
Miller XR-Aluma-Pro™ 25 Ft. Water 301572
$3,222.00
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Product Number: 301572
RACK,4-PK XMT 350 FIELDPRO POLA RACK,4-PK XMT 350 FIELDPRO POLA
Miller XMT® 350 FieldPro™ with Polarity Reversing Narrow 4-Pack Rack f...
$35,786.00
$41,331.00* You Save $5,545.00
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Product Number: 907742
Dynasty 800 TIGRunner Dynasty 800 TIGRunner
Miller Dynasty® 800 208-575 V, TIGRunner 907719001
$20,430.00
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Product Number: 907719001
PKG,DYNASTY 800 WIRELESS FOOT C PKG,DYNASTY 800 WIRELESS FOOT C
Miller Dynasty® 800 Wireless Foot Control Complete 951875
$23,444.00
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Product Number: 951875
PKG,DYNASTY 280 DX VS WIRELESS PKG,DYNASTY 280 DX VS WIRELESS
Miller Dynasty 280 DX VS Wireless 951878
$15,947.00
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Product Number: 951878
BIG BLUE 400 PRO (CAT) W/ WIC BIG BLUE 400 PRO (CAT) W/ WIC
Miller Big Blue 400 Pro W/ WIC 907774003
$20,633.00
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Product Number: 907774003
SYNCROWAVE 400 TIGRUNNER 208/23 SYNCROWAVE 400 TIGRUNNER 208/23
Miller Syncrowave 400- Tig Runner 907783001
$11,404.00
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Product Number: 907783001
PKG,MR INV 352 MPA PLUS SYSTEM PKG,MR INV 352 MPA PLUS SYSTEM
Miller Invision™ 352 MPa, D-74 MPa Plus (Dual), 2 Bernard™ BTB 400 A 1...
$16,204.00
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Product Number: 951500
PKG,DIMENSION 650 MIGRUNNER PKG,DIMENSION 650 MIGRUNNER
Miller Dimension™ 650 380/460 V MIGRunner™ Package 951637
$13,919.00
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Product Number: 951637
PKG,XMT 350 FIELDPRO,ARCREACH S PKG,XMT 350 FIELDPRO,ARCREACH S
Miller XMT® 350 FieldPro™, Tweco®, ArcReach® Stick/TIG Remote Pkg 9517...
$7,792.00
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Product Number: 951736
PKG,XMT 350 FIELDPRO,AR SMART F PKG,XMT 350 FIELDPRO,AR SMART F
Miller XMT® 350 FieldPro™, Tweco®, ArcReach® Smart Feeder, Bernard™ Pi...
$14,475.00
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Product Number: 951738
PKG,DYNASTY 280 DX VS FINGER CO PKG,DYNASTY 280 DX VS FINGER CO
Miller PKG,DYNASTY 280 DX VS FINGER CO 951796
$13,264.00
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Product Number: 951796
PKG,DYNASTY 280 DX VS FOOT CONT PKG,DYNASTY 280 DX VS FOOT CONT
Miller PKG,DYNASTY 280 DX VS FOOT CONT 951797
$13,379.00
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Product Number: 951797
PKG,DYNASTY 280 DX VS FINGER CO PKG,DYNASTY 280 DX VS FINGER CO
Miller PKG,DYNASTY 280 DX VS FINGER CO 951798
$12,870.00
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Product Number: 951798
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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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