Best Welder for Aluminum (MIG/TIG)

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Fast, FREE shipping to the lower 48 states for Cutmaster 152 Plasma System! Cutmaster 152, 120 Amp, SL100, 20 ft Leads, 208-230V, 1Ph
Cutmaster 152, 120 Amp, SL100, 20 ft Leads, 208-230V, 1Ph
$5,499.00
$6,899.00
Cutmaster 102 #1-1331-1 Thermal Dynamics Cutmaster 102, 100 Amp, SL100, 50 ft Leads, 208-230V, 1Ph
Thermal Dynamics Cutmaster 102, 100 Amp, SL100, 50 ft Leads, 208-230V, 1Ph
$4,699.00
$5,649.00
long lasting Thermal Dynamics Cutmaster 58, 20 ft. SL60QD, 208-230 with rebate Thermal Dynamics Cutmaster 58, 20 ft. SL60QD, 208-230 VAC
Thermal Dynamics Cutmaster 58, 20 ft. SL60QD, 208-230 VAC
$2,399.00
$2,999.00
45 degree angle white background product shot Thermal Dynamics Cutmaster 60i
Thermal Dynamics Cutmaster 60i
$2,113.25
$2,875.00
Thermal Dynamics Cutmaster 102 Plasma Cutter #1-1330-1
Thermal Dynamics Cutmaster 102 230V Plasma Cutting System
$4,399.00
$5,499.00
Cheapest online Thermal Dynamics Cutmaster 58 1-5830-2 20 ft. Lead W/SL60QD Torch blogging reviews Thermal Dynamics Cutmaster 58, 20 ft. Lead W/SL60QD Torch
Thermal Dynamics Cutmaster 58, 20 ft. Lead W/SL60QD Torch
$2,399.00
$2,999.00
ESAB REBEL EMP 235IC MIG/STICK/TIG WELDER WITH CART #0558012704 ESAB REBEL EMP 235IC MIG/STICK/TIG WELDER WITH CART 0558012704
ESAB REBEL EMP 235IC MIG/STICK/TIG WELDER WITH CART 0558012704
$3,349.00
$4,099.00
Cutmaster 1-1330-5 Cutmaster 102, 100 Amp, SL100, 20 ft Leads, 600V, 3Ph
Cutmaster 102, 100 Amp, SL100, 20 ft Leads, 600V, 3Ph
$4,399.00
$5,499.00
Save on ESAB Rebel™ EMP 205ic AC/DC 0558102553 with Winter Saving Rebate ESAB Rebel™ EMP 205ic AC/DC
ESAB Rebel™ EMP 205ic AC/DC
$4,099.00
$4,949.00
Cutmaster 1-1130-5 Cutmaster 82, 80 Amp, SL60, 20 ft Leads, 600V, 3Ph
Cutmaster 82, 80 Amp, SL60, 20 ft Leads, 600V, 3Ph
$3,499.00
$4,299.00
500564Airforce
Hobart AirForce™ 12ci Plasma Cutter #500564
$1,233.10
$1,298.00
60i machine Thermal Dynamics Cutmaster 60i #1-5631-1 w/ 50' Torch
Thermal Dynamics Cutmaster 60i #1-5631-1 w/ 50' Torch
$3,099.00
$3,649.00
Forney 220 AC/DC TIG Welder Package #420 Forney 220 AC/DC TIG Welder Package #420
Forney 220 AC/DC TIG Welder Package #420
$2,399.99
85 A FlushCut SmartSYNC Hypertherm Cartridge #428953
85 A FlushCut SmartSYNC Cartridge
$101.00
Miller Big Blue 450 Duo CST (Mitsubishi) 907477 Miller Big Blue 450 Duo CST (Mitsubishi)
Miller Big Blue 450 Duo CST (Mitsubishi)
$31,971.30
$33,654.00
Powermax45 XP #088126 on sale - Reduced price & free gloves
Powermax45 XP w/ 20' 75° Hand Torch (460V)
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$2,925.00
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Powermax45 XP w/ 20' 75° Hand Torch (220V)
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Hypertherm Powermax45 XP #088113 on sale - Reduced price & free gloves
Powermax45 XP w/ 20' 75° Hand Torch, CPC Port (220V)
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Hypertherm Powermax 45 XP #088114 on sale - Reduced price & free gloves
Powermax45 XP w/ 50' 75° Hand Torch (220V)
$2,691.55
$2,850.00
Hypertherm Powermax 45 XP #088115 on sale - Reduced price & free gloves
Powermax45 XP w/ CPC, 50' 75° Hand Torch (220V)
$2,809.60
$2,975.00
Hypertherm Powermax 45 XP #088124 on sale - Reduced price & free gloves
Powermax45 XP w/ 20' 75° & 15° Torches, CPC (220V)
$2,691.55
$2,850.00
Hypertherm Powermax45 XP #088117 on sale - Reduced price & free gloves
Powermax45 XP w/ 35' 180° Machine Torch, CPC, Remote (220V)
$2,998.50
$3,175.00
Hypertherm Powermax45 XP #088118 on sale - Reduced price & free gloves
Powermax45 XP w/ 50' 180° Machine Torch, CPC, Remote (220V)
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Hypertherm Powermax45 XP #088121 on sale - Reduced price & free gloves
Powermax45 XP w/ 25' 180° Machine Torch, CPC (220V)
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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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Jackson Nemesis Safety Glasses Smoke/Mirror #25688
Jackson Nemesis Safety Glasses Smoke/Mirror #25688
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Jackson Safety VIBE Earmuff #20774
Jackson Safety, VIBE Earmuff
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Miller Digital Elite Auto Darkening Welding Helmet #257213
Miller Digital Elite AutoDarkening Welding Helmet 'Black'
$289.00
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Tillman Green Sleeves
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Miller
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Hypertherm Powermax 65/85/105 Nozzle 65A #220819 (Pack of 5) Powermax 65
Hypertherm Powermax 65/85/105 Nozzle 65A (5-pk)
$38.10
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Tillman Backhand Pads Part#550
Tillman Backhand Pad
$13.55
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Miller Fastip Contact Tips #2061(86,87,88,89,90)
Miller Fastip Contact Tips 2061(86,87,88,89,90)
$49.30
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Miller Millermatic 211 #907614 - 6 Free items with purchase Millermatic 211 Auto-Set Mig Welder
Millermatic 211 Auto-Set Mig Welder
$1,935.00
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