Aluminum Gas Welding: The Ultimate Guide 2022

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Beginners might see Aluminum gas welding can be complicated, but it's when you don't have essential knowledge, tools, and materials. Once you have all these in place, welding is straightforward. The way you decide to do it depends on you as long you reach to get what you wished for.

The report contains useful information on what you need to consider before gas welding aluminum, tips to get started, tools, and materials you need. It would help if you were much keen when working gas welding aluminum because the process is tricky. More so, it would help if you carried out excellent preparation and setup before kicking off the process.

The difference between these two welding techniques is the final product. The drag aluminum gas welding technique is useful when you don't have enough gas coverage for cleaning aluminum. This results in unclear and smart welding.

On the other hand, the push aluminum gas welding technique involves the correct gas level coverage. The final result is more precise and attractive. Now you are the one to decide which way to go
Comparison of Push and Drag Aluminum Gas Welding Techniques
You Can Check Our New Welder Duty Cycle Calculator

General Tool Considerations

Welding aluminum requires some tool considerations, and many experts find themselves using an oxy-fuel torch. There are two types of the oxy-fuel torch, i.e., conventional victor-style mid-duty combo torch that works incredibly.

The other type is the DHC2000, Detroit Torch, and Mfg. Company. Each of these units has its weaknesses and strengths, making it preferable and better than handling a specific application.

Many experienced welders affirm that using a conventional torch is quite tricky. Some even say that sometimes, they end penetrating through a molten weld pool. Replacing hydrogen with acetylene places you in a better position to control and monitor the weld puddle.

That may sound true, but I plan to work on enough aluminum to confirm or justify the statement. Spending additional money to buy a separate regulator, hydrogen cylinder, and hose can be costly. For this reason, I prefer swapping out my torch instead of spending on fuel.

Compared to the conventional torch, a DHC2000 seems to deliver a more concentrated and softer flame. Using this type of tool is a bit easier, not complicated, when welding particular metals such as aluminum and stainless steel. However, the DHC2000 device is only suitable for welding small and medium-sized materials and projects. Therefore, if most of your project involves materials of 3/8" thickness, then use this machine.

Other Required Tools & Materials

It will be a joke of the decade if you jump to aluminum gas welding without assembling essential materials and tools. For this reason, it's advisable to ensure all the accessories you require are near. Below are some of the standard tools and materials you need for the task.

  • A Welder, it's typically the first tool you need to include on your list. The welder is the leading equipment to supply current via the electrode, supporting aluminum welding. Invest in a machine that features sufficient functionality and power to handle aluminum welding effortlessly.
  • Tungsten Electrode; there's no way you can weld without electrodes. For this reason, you'll have to buy electrodes based on the type of welding you intend to accomplish. For example, TIG welding usually utilizes non-consumable tungsten electrodes.
  • Shielding Gas; for a professional welding result, you need a shielding gas to protect your work piece from atmospheric contamination. Here, argon is the main gas, but sometimes you can use 3% helium in the gas for the stable arc.
  • Filler Metals; buy filler metals that are only meant for aluminum welding. The two metals that act as fillers in aluminum welding are; 5356and 4043 alloys.
  • Welding Clamps; some welders overlook this requirement. Using the C-clamp while welding is significant because the work piece may move around, ruining your project. Get one for better finishing.
  • Sheet Metal Gauge's primary purpose is to measure the metal thickness accurately.
  • An Angle Grinder; is another essential requirement, useful for grinding and clearing away all kinds of paint and rust from your work piece surface. This machine prevents post-welding contamination.
  • Welding Magnets; are useful for sticking the work piece into your desired angles. Your metal should not move around while welding is in progress.

Weld Preparation And Setup

Before you kick off the welding process, there's a need to ensure your work piece surface is clear. It should be free from any sorts of debris, grease, dirt, etc. Fluxing is necessary to mitigate contaminants, but you can still use a stainless steel brush to scrub the metal surface. Use a clean piece of cloth to wipe the metal surface before welding.

Beveling the edges is required when joining ¼ thickness materials; it enhances excellent weld penetration. The material thickness might be the primary consideration, but you also need to consider other factors. Some of these extra considerations include; the size of the place to be welded, the heat required, pace for laying bead, etc.

Many welders overlook the work surface; if your work piece lies flat on the metallic bench, its top will probably act as a heat sink, driving heat from the welded part. This can be challenging when welding aluminum. Unlike copper, aluminum material features higher thermal conductivity; the heat always moves quickly away from the welded zone.

Therefore, you need to apply some tips like preheating the metal and setting it on top of firebricks before repair.

Preheat Temperature Checking Technique

Temperature gauges remain one of the best ways to check your metal's preheat temperature, but sometimes you may lack such devices. When you don't have temperature gauges or pyrolytic, below are other ways to gauge the correct preheat temperatures.

Char test; take a pine stick and rub one end on the preheated metal. This stick chars at correct temperatures, turning darker.

Carpenter's chalk; use a blue carpenter's chalk to mark your metal. When the blue line turns white, your metal is adequately preheated.

Hammer test; using a hammer is another way to determine if the metal is properly preheated. Lightly tap the metal using a hand hammer; it will lose its ring at proper preheated temperature.

Carburizing test; this is another method that requires you to carburize the metal surface, sooting the whole body. When torching, soot will disappear, but you need to be careful not to interfere with the fluxed part; soot may cause porosity.

Step By Step Procedure Of Aluminum Gas Welding

Step 1: Safety

Welding is a dangerous task requiring a lot of attention concerning safety measures. Your safety, therefore, should come first because the art involves flames and fire. A small mistake may leave you with injuries on your body. Wear a welding jacket, chaps, boots, and gloves before touching the machine.

Additionally, you will have to put on a respirator or a mask before initiating the project.

Step 2: Clean the filler rod and work piece

An angle grinder is the best tool you will use to clean your staff before welding. Cleaning is necessary because aluminum material tends to form an aluminum oxide layer on its surface. Such coatings delay the melting time than on normal circumstances.

The aluminum material may have paints and dust on its surface, causing contamination. Therefore, grinding is necessary before welding. Use abrasive cleaning pads to clean filler rods.

Step 3: Clamping

Under this step, you must seek C-clamps' help to hold the work piece into your desired position. Sometimes you may decide to clamp your work piece down the welding table. You want to ensure the metals are tightly controlled; they should not move apart.

Step 4: preheat your work piece

As discussed above, you know how to preheat aluminum metal before carrying out any welding application properly. Preheating is essential to make the joining task much more comfortable. You can put your work piece in an oven or use propane for preheating correctly. The preheating job should range from 300-400 degrees (F).

Step 5: Configuring your welder

This is a critical step that you need to be much careful about. Before you set up the amperage, you must measure your work piece thickness correctly. Try using a sheet metal gauge to perform the task. For my case, I prefer using 1amp power per 0.001-inch metal thickness. Configure the welder once you've identified the exact thickness.

Step 6: Set up the torch

This step involves the simple art of inserting the electrode into the welding torch. A small part of your electrode should be visible outside the feeder; it shouldn't be massive as the nozzle size. Sharpen the edge of your electrode manually.

Step 7: Determining the correct angle

This step involves positioning your torch at a correct angle, above the joint you want to work on. 75% is the standard angle to place the torch from the joint tip.

Step 8: Drawing a suitable weld puddle

The step is straightforward as it requires you to start pushing the trigger or foot puddle, powering the torch to melt the work piece. You have to deliver a pool that isn't massive than your filler's diameter. Afterward, you will need to fill out your joint part through non-stop filler rod feeding. Remember, you should not insert the filler rod unless you are through with puddle production.

Step 9: Dipping the filler rod after few seconds

The last thing you should do is ensure you are continuously feeding filler rods. After a few seconds, you should do this until the entire region is fully welded. Solidify the puddle by reducing the current to prevent your work piece from cracking.

Tips For Getting Started

Understand the metal you're using; aluminum has a higher thermal conductivity level. Unlike steel, TIG welding aluminum can be a bit faster.

Wire brush; use brass or copper wire brush to brush the material. Scrubbing the workpiece surface will break and remove the oxide coating. DON'T use a steel wire brush. It will contaminate the material. While brushing, you will realize that the metal begins to dull.

Clean the metal before welding; use denatured alcohol to wipe down filler rod and base material. If you have acetone, to hesitate to use it in the absence of denatured alcohol.

Consider the torching angel; torch angle is essential because the filler rod tens to ball faster before you even think of dipping. So, ensure the feeding is steady and quicker.

Practice makes it perfect; the more you task you handle, the more experience you garner. It would help if you worked on different welding projects to become an expert; don't boost yourself, yet you only venture into one category.


Aluminum gas welding is becoming more popular, and welders should have the necessary skills. Without a complete guide, you might end up messing with your welding project and even get some injuries. The art requires some hands-on training; it might be formal.

Thank God the above discussion has comprehensive information to help you correctly gas weld aluminum.


What process should you use?

AC is the best way to weld aluminum since its positive ½ cycle offers 'cleaning' action. The negative ½ processes provide penetration.

What shielding gas should I use when welding aluminum?

The commonly used shielding gases in TIG welding aluminum are helium and argon. It's allowed to use these gases while pure or their mixture.

What gas do you use when welding aluminum?

Your gas cylinder might contain oxy acetylene, natural hydrogen gas, among other flammable gas. Oxyacetylene gas remains the best and commonly used one in welding aluminum.

Can you use 75 argon 25 CO2 to weld aluminum?

No, CO2 is reactive, leading to oxidation. The recommended amount of argon in welding aluminum is 25%.

How do you weld Aluminum with oxyacetylene?

Start by setting up the tool before lighting it up. Ensure your workpiece is ok; initiate the filler rod and leave the workpiece to cool down.

Can I weld aluminum without gas?

It's challenging, and if not careful, you can get yourself into messes. Let only the experienced welders use weld without gas.

Can you weld aluminum to steel?

Yes, you can achieve this through mechanical fastening or adhesive bonding.

Can you use a stick welder to weld aluminum?

It's not advisable because molten aluminum tends to react efficiently with atmospheric oxygen.

Can you weld aluminum with c25 gas?

TIG welding should only be done using an inert gas, helium, argon, or mixes.

Last Updated on January 6, 2022 by weldinghubs

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