Using a TIG Welder for Aluminum
What is TIG Welding Aluminum?
TIG welding, short for Tungsten Inert Gas, is a form of arc welding that produces a weld through a non-consumable tungsten electrode. Another name for the TIG welder is GTAW (Gas Tungsten Arc Welder). TIG welders use an inert gas, usually argon, to shield the weld puddle from airborne contaminants. TIG welders usually require a filler metal as well. Some welds, known as autogenous or fusion welds, don’t require a filler metal. TIG welding aluminum requires a constant-current power supply conducted across the arc through a column of ionized gas and vapors called plasma.
Most experts say TIG welding aluminum is the best method to weld aluminum since it produces, clean, high-quality welds. Unlike other types of welding, there are no sparks or spatter as long as the material to be welded is clean, and no slag to block your view of the weld puddle. TIG welding is clean, producing no smoke or fumes. Just one shielding gas, Argon, can be used for all applications. TIG welders are versatile, able to weld more materials than any other process. Besides aluminum, TIG welders can weld a variety of non-ferrous metals, including stainless steel, nickel and chrome alloys, brass, copper, bronze, and gold.
What basic equipment does TIG Welding Aluminum require?
Besides the welding unit itself, TIG welding often requires a high frequency generator to strike the welding arc. Instead of a generator, an arc can be generated with a “scratch start.” For a scratch start, the operator turns on the power to the welder and scratches the electrode against the metal to be worked on. The disadvantage of scratch welding is that the weld and electrode can become contaminated. Some TIG welders have a mode called “lift arc” or “touch start” that can strike the arc without a separate generator.
TIG Welders are expensive, and most people can only justify purchasing one if they’re planning to make significant money welding. Six thousand dollars will buy a higher-end unit with many features to do quality TIG welding aluminum. One advantage of purchasing a top-of-the-line unit is more amperage, enabling you to weld thicker metal. Bottom-of-the-line TIG welders, good enough for farmers or hobbyists that only need them for occasional jobs, run about $2500, but the quality will be much lower.
Is TIG Welding Aluminum Difficult?
Most welders consider manual TIG Welding the most difficult welding process to master, but with practice most people with good dexterity can acquire enough skill for the average welding project. Because a short arc length must be maintained, the welder must pay attention to avoid contact between the electrode and the piece being worked upon. As with torch welding, TIG welding requires two hands. In most applications, the operator must manually feed the filler metal into the area being welded while operating the welding torch with the other. Welds that don’t require filler material don’t demand handling the filler and the welding torch at once, and aren’t as difficult.