Welding Aluminum

Sonny Jenkins · Post by **Sonny Jenkins** » 20 Mar 2022 4:18 pm

Wondering if there is anyone on here that welds aluminum. I've done some old time stick welding,,,and even some mig,,,but I know very little about the process of welding aluminum. I tried some aluminum sticks,,like brazing rod with a torch,,,even used my little jewelers torch which can control the heat very well,,,but the difference in temperature is so critical,,,and it doesn't actually melt into the work. You tube makes that method look pretty good but didn't work that well for me.

Tim Toberer · Post by **Tim Toberer** » 21 Mar 2022 5:34 am

I think AC tig is the way to go. These work for light duty repairs. https://www.menards.com/main/tools/weld ... 532121.htm

John Larson · Post by **John Larson** » 21 Mar 2022 5:52 am

TIG or MIG is the way to go.
Aluminum is very difficult to weld normally.
It's an exercise in futility to try and stick weld it in my opinion.
Aluminum has a very tough oxidation layer to break through when welding it so make sure the surface you are trying to weld is clean with acetone wipes or such.

Ross Shafer · Post by **Ross Shafer** » 21 Mar 2022 9:40 am

Hi Sonny,

Tig is definitely your best route for welding the type of things you'd want to put together. Mig is much more suited to less aesthetically important production type stuff.

Other than the first few prototypes which were bolted together...I tig weld all the Sierra aluminum frames.

Bobby D. Jones · Post by **Bobby D. Jones** » 21 Mar 2022 5:17 pm

Tig welding would be the best for small (Steel guitar) parts.
It gives you better heat control on small parts. And add only the amount of filler rod to make a good weld. Makes for smoother, Smaller welds with easier fitting and finishing.

Ronald Sikes · Post by **Ronald Sikes** » 21 Mar 2022 5:26 pm

Sonny, I have a high frequency tig welder . I might could help you out if you need something. Not that far from you.

Tim Toberer · Post by **Tim Toberer** » 22 Mar 2022 2:55 pm

Are you guys using dc rigs? I have a small stick welder I’m considering turning into a tig. It’s dc so I’m not sure if it will work for aluminum.

Ronald Sikes · Post by **Ronald Sikes** » 22 Mar 2022 2:58 pm

Tim , Tig welding stainless is DC. Aluminum is AC. The one I have has a foot control for your heat , and a water cooled torch.

J D Sauser · Post by **J D Sauser** » 22 Mar 2022 3:22 pm

Ronald Sikes wrote:Sonny, I have a high frequency tig welder . I might could help you out if you need something. Not that far from you.

Yes, TIG is what we use at our SuperCar RestoMod shop. It still takes a very CAPABLE Professional to do a clean and sound weld. Aluminum is not a fun material to go at with a grinder!

Ronald. IF you are indeed offering your "services" for prototypers, please feel free to list yourself in the "Parts Builders"-Thread:

https://bb.steelguitarforum.com/viewtopic.php?t=378296

as your offer could go under some times on this thread.

Thanks!... J-D.

Tim Toberer · Post by **Tim Toberer** » 23 Mar 2022 5:26 am

. Aluminum is AC. The one I have has a foot control for your heat , and a water cooled torch.

Ok thanks that what I thought. I wish there was a cheaper option.

Andy DePaule · Post by **Andy DePaule** » 10 Apr 2022 7:48 am

TIG is best for sure, but they are not cheap.
One of my sons just sent me a wire welder. It is a Harbor Freight one that they sell for about $100 and sometimes a little less.
My son got it in some kind of trade and said he used it and liked the way it worked. He has several kinds of welders so I trust his judgement better than my own.

He said it was for metal and didn't think it would work with aluminum.
However, I watched a couple of you tube videos and you can use it for aluminum welding if you use a special wire with it.
Sorry I don't remember the kind of wire, but will look into that when I get home and give the welder a try out. It's still in the box because I've been so busy getting my garage workshop organized.
Funny how fast we fill up a two car garage with tools and then need a four car garage.

Darvin Willhoite · Post by **Darvin Willhoite** » 10 Apr 2022 7:16 pm

The TIG welder is just part of the cost, you have to have a bottle of inert gas for shielding. The bottle and gas is up to about $600 in my area. You only have to pay once for the bottle, then you can exchange it for a full one when it runs out. I think my last exchange was about $40.00.

Doug Earnest · Post by **Doug Earnest** » 11 Apr 2022 3:14 pm

You will be much better off in terms of time, money, and frustration saved to go find someone who is equipped to do fine TIG welding on aluminum and regularly does so. Pay them whatever they ask.

Sonny Jenkins · Post by **Sonny Jenkins** » 11 Apr 2022 4:41 pm

Around here $150 "set up fee" is frequently what they ask. For a Builder or Manufacturer that can provide them several hours work that may be fine,,,,but for my 15-20 minutes worth of welding,,,,,,and certainly would not justify the cost of buying equipment. VERY fortunate for me I've had a couple of VERY kind offers from "forum family" members to help me out should I need it. I can normally find a way to get around the need for welding,,,but,,,sometimes,,,,,,???

Robert B Murphy · Post by **Robert B Murphy** » 13 Apr 2022 8:07 pm

For fine aluminum TIG is the only way to go. The gas has to be 100% argon and not the 75/25 ar/co2 usually found at the local welding supply (LWS) vendor. The aluminum has to be really clean (sanding and solvent) and the dc offset to the ac current has to be right to float off the oxide layer on the puddle. The lanthanated or thoriated electrode tip needs to be ground correctly on a diamond wheel and by the way, the dust is toxic. Then you need an experienced hand to get a good result. Go to a pro unless you're really interested in learning how to do it and money is no object.

Aluminum burns at welding temperatures. It must be melted in an inert atmosphere. There is a coating made for filler, not a flux, that makes a little gas bubble around the puddle to protect it from oxidation but you need an arc to make the gas bubble and by then you already have slag. Don't expect much from it.

Scott Duckworth · Post by **Scott Duckworth** » 14 Apr 2022 3:20 pm

Andy DePaule wrote:TIG is best for sure, but they are not cheap.
One of my sons just sent me a wire welder. It is a Harbor Freight one that they sell for about $100 and sometimes a little less.
My son got it in some kind of trade and said he used it and liked the way it worked. He has several kinds of welders so I trust his judgement better than my own.

He said it was for metal and didn't think it would work with aluminum.
However, I watched a couple of you tube videos and you can use it for aluminum welding if you use a special wire with it.
Sorry I don't remember the kind of wire, but will look into that when I get home and give the welder a try out. It's still in the box because I've been so busy getting my garage workshop organized.
Funny how fast we fill up a two car garage with tools and then need a four car garage.

Just a tip on the cheapee Harbor Freight welder (and others like it). There are instructions on the web how to convert those to DC welders. Makes them weld with a lot less spatter using flux core wire. Just a thought for general usage.

Andy DePaule · Post by **Andy DePaule** » 14 Apr 2022 4:22 pm

Scott Duckworth wrote:
Andy DePaule wrote:TIG is best for sure, but they are not cheap.
One of my sons just sent me a wire welder. It is a Harbor Freight one that they sell for about $100 and sometimes a little less.
My son got it in some kind of trade and said he used it and liked the way it worked. He has several kinds of welders so I trust his judgement better than my own.

He said it was for metal and didn't think it would work with aluminum.
However, I watched a couple of you tube videos and you can use it for aluminum welding if you use a special wire with it.
Sorry I don't remember the kind of wire, but will look into that when I get home and give the welder a try out. It's still in the box because I've been so busy getting my garage workshop organized.
Funny how fast we fill up a two car garage with tools and then need a four car garage.
Just a tip on the cheapee Harbor Freight welder (and others like it). There are instructions on the web how to convert those to DC welders. Makes them weld with a lot less spatter using flux core wire. Just a thought for general usage.

Hi Scott,
Thanks for the tip. I certainly can use all the help I can get where welding is concerned.
Best wishes,
Andy

Darryl Coyne · Post by **Darryl Coyne** » 27 May 2022 4:35 pm

I can see this thread has been open for a while so maybe it is no longer directly relevant but I like to help where I can. If you have already found a solution, maybe this will help someone else.
On a build I completed about two years ago, I used the "alumiweld" sticks that are available at Harbor Freight to fasten 1" aluminum blocks to bent 1/8" aluminum end plates. While certainly not close to a TIG joint, I have found that the joints look decent and hold up very well. It is a little tricky getting the hang of using the sticks. What worked for me was clamping the block to the end plate and heating the assembly on the stove until it was just starting to deform a little. Once hot, I shut off the burner, then applied a propane torch and alternately worked in the rod and scratched at the joint surfaces with a small screwdriver. The scratching seems to help keep a new oxide layer from forming just long enough for the "weld" to adhere. The first few were difficult but not bad once I got the hang of it. The picture shows one of the finished joints.

Tim Toberer · Post by **Tim Toberer** » 28 May 2022 5:27 am

There are a number of these out there. I have some from Menards that work ok. It is very tough to get them to stick but it does work. I wondered if the Harbor Freight sticks are any better. I like your tip about preheating the metal and scratching. I think this is still relevant. I will never own a proper tig torch, so this is the solution I like. There are some Youtube videos of people testing the strength of these and it seems pretty good. It is probably not acceptable in some applications however.

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Welding Aluminum

Welding Aluminum

TIG is best for sure, but....

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Re: TIG is best for sure, but....