TIG welders are expensive, so consider contacting a local welding supply store or home hardware outlet about rental possibilities. It’s possible to weld aluminum with other welding processes, such as MIG welding, but TIG welding is the method most suitable for beginners.
You can find aluminum filler rods at hardware or home improvement stores, such as Harbor Freight or Home Depot. Opt for either a 4043 or 5356 alloy. [3] X Research source Use a filler rod that is equal in size to the tungsten electrode. [4] X Research source
Gas needs to be acquired from authorized gas dealers. Most welding supply stores will be able to provide gas or refer you to an outlet that can. If you’re renting the TIG welder, purchase your argon canister when you pick up the welder.
Try to find a shirt that is made of 100% cotton. Make sure that your pants do not have cuffs that can catch molten metal.
Your welding gloves should be insulated and fire-resistant. Keep a fire extinguisher easily accessible in case of any stray sparks. Try to use a helmet with a lens that automatically darkens during the welding process. The lens should be rated at 10-13 shade.
Double check all hoses and connections. Check for and replace any cracked or corroded parts. Replace any dented or rusted tanks. Check your wires and cords and fix any that are frayed or nicked.
If you use wire brushes to clean the aluminum, make sure to use brushes that are new or have only been used to clean aluminum. Brushes that have been used to clean other metals may leave traces of those metals behind, which can affect the quality of your weld. Spray the joints with electrical cleaner. Rinse the work piece in water, and then allow it to dry thoroughly. Scrub the aluminum with a stainless steel wool scrubber, such as a Scotch Brite scrubbing pad, to finish the cleaning process. [10] X Research source
If you can, suspend the area you will be welding above the table. This will make the heat transfer more effective and create better weld penetration. Consider clamping the workpiece to a heat sink, such as copper. This will ensure that the heat from the weld will transfer safely without warping your work or damaging anything else in your workspace. [12] X Research source
When welding thick pieces of aluminum, welding without preheating can lead to a very weak, shallow bond. [13] X Research source
You can also ensure protection from fumes by using welding fume extractor machines. [14] X Research source
If you pull the tip too far away, it will cause the arc to spread too much and the weld will become difficult to control. [15] X Research source
If the filler and the tip come into contact, your weld will be contaminated and lose structural integrity. [16] X Research source
If you don’t have a lot of experience with welding, practice with some scrap aluminum and try different settings until you find what works best for you. Getting the settings right can make a big difference in the quality of your weld, and environmental factors can affect which setting works best.
If you’re having trouble starting the arc, your amperage is likely too low. Adjust your amperage setting and try again. [20] X Research source
As you weld, heat will increase throughout the workpiece. Use your foot pedal to lower the amperage as you go to maintain control of the puddle. [21] X Research source While you weld, pay close attention to your puddle size. If it’s too big or too small, you may burn through your material or not get a solid weld.
Give the metal plenty of time to cool before you touch the finished product.
