No matter how expert you are, finishing the expected job will be very challenging and painful.
Especially welding the metal like Aluminum that holds the very complex chemical and physical structure that always needs extra effort and practice for the technical stuff.
When we talk to about welding aluminum, the main problem is burn through rate, so that, you have to very careful while welding.
Before we jump to weld aluminum, something we need to keep in mind is, better control and travel speed, otherwise, you will burn your work piece.
As a welder, you already know that without a good welder you can't expect all the features you need to weld aluminum.
To sort this problem out, we have come up with a list of the most powerful welder that's are surprisingly good for Aluminum.
If you need a welder welding Aluminum, you can chose among these welding machines to avoid blunders.
Moreover, we have added some further information regarding welding and welder that you should know before buying your machine.
Let's check it out first....
6 Best Welders for Aluminum (TIG and MIG)
1. AHP Alpha TIG 200 Amp IGBT AC DC Tig/Stick Welder- TOP PICK
Your search for a professional-grade aluminum welder with an affordable price ends here. Because the AHP Alpha TIG 200x can be your go-to option for TIG welding.
Let's dive in to find how this fulfills your welding needs.
Professional yet affordable!
The AHP Alpha TIG 200x is a professional grade welder with stick function gives you a good deal at an affordable price.
Seriously, the quality is way too good for the price of this thing.
Reliable with the power source...
Equipped with IGBT technology the Alpha TIG 200x ensures reliability and a longer-lasting power source.
Also, the Pulse Width Modulation helps it to get an efficient performance on the power source.
It provides a complete array of pulse features and giving control over the cleaning for AC.
Based on the more exceptional performance on the 110v class alongside 220v, this is one of the most versatile welders you can get at this price.
The AHP AlphaTIG 200x gives you the ease of usage and much better control with its special foot pedal feature.
2. Hobart Handler 210 MVP MIG Welder Dual-Voltage- RUNNER UP
If you are looking for a MIG welder, then The Hobart Handler 210MVP is the best one you can get out there as suggested by professional welders.
Now it's time to justify why I chose this to be in this aluminum welder review.
Switch powers with ease...
Now you won't need any additional tools to switch between 115v or 230v. You can switch between them with just as a twist.
With the smart intelligence, it automatically adjusts to the correct option delivering greater arc performance no matter the source.
With the Hobart Handler 210MVP, you can weld body panels, trailer frames, farm equipment, gun/bow racks, trailer frames and hitches and many more.
So, it gives you a variety of choices to work on.
You don't need to go through much hassle to set this machine up. All you have to do is follow along with the instruction manual that comes with the box.
Well, that's it you're good to go now. It just takes a few minutes of your time to get into action.
3. Millermatic 350P Aluminum Series Flux Core, MIG Welder- PREMIUM MIG (For Beginners)
Miller is forever the consumer's favorite welder. Though I can't claim that it's excellent on heavy industrial welding, a professional welder and a DIY enthusiast must find that useful.
Alright! Let's sneak-peak into the key features
MIG Welding & Additional Attachments...
Here Miller electric welder holds MIG welding formula which not only effective on household arcs but also farming and DIYs. Even artists seem to be contented with efficiency.
Now, you might not know that this one comes with additional attachments.
To meet with your different welding fetish, it has tailored specific attachments.
You just need to glance over the instruction manual to narrow down the proper use of each of them.
Probably, it's not the sleekest one, but the smart configuration is bound to impress you.
Although I think it could be lighter in weight, yet storing this one won't be a tight job.
Miller has crafted this one at 34-inch height, 19 In overall width and 41 inches.
Overall depth, which I think pretty smart as an electric welder.
Well, the material Thickness is 1/2 Inch which is undoubtedly impressive.
The heavy arcs and agility depend on the material thickness. Hence, if the material thickness is somehow abundant, then the performance becomes more convenient.
4. LOTOS TIG 200A AC/DC Aluminum Tig Welder
Liked by most of the users till now LOTOS TIG200ACDC 200A is a compact welder that offers a significant class to your welding needs.
This little welder can be used in various situations with its multi-functional control.
Let's see what other distinct features this has to offer.
Better power-efficient welding output...
The Lotos TIG 200A AC/DC gives you an intimidating 200amp output. Which can give you the best experience on TIG welding.
Well, it's not only for welding aluminum. You can weld stainless steel as well as thinner gauge materials.
It's 80% power efficiency makes it much more enticing for the users.
Specializing in Aluminum
With the square-wave inverter technology, it becomes a prominent welder for aluminum materials.
Multiple voltage options
Equipped with easy switching between the voltage modes, the Lotos TIG200ACDC 200A is capable of running on two different voltages with two different frequencies.
Yeah, that's pretty convenient for a compact size welding machine.
The Lotos TIG200ACDC 200A comes with a foot pedal and hand torch, enabling the users to have great control over the welding.
It also provides heat control for welding. Now you will want to have control over your welding.
It is just making sure that it happens to every aspect.
5. Hobart 500551 EZ-TIG 165i AC/DC TIG Welder 230V
If you go through the previous versions of Hobart, you'll find this one better and more versatile.
Along with welding tasks, it also shines on soldering. Usually, you won't get multi-purpose usage at such a price.
Easy to set up...
It is effortless to set up. Just plug-in, connect shielding gas, choose the thickness and material and that's it; ready to weld.
The lightweight design makes it portable and more acceptable.
The welder is not the only expert to weld Aluminum but also other materials, and it makes it more worthy.
You may don't want to spend money on a welder that is built for one purpose. But when it offers multiple advantages at a package, there is no reason to reject it.
The acceptance of a product depends not only on the feature, but it is also important to be durable. Miller Electric won't disappoint you at all.
6. LOTOS MIG 175AMP MIG Welder- BEST BUDGET
Whether you are a professional or a newbie, the LOTOS MIG175 175AMP Mig Welder is always recommended by the experts.
But what makes it that reliable?
Check it out-
Cut, weld, and Build...
Sounds easy? LOTOS makes welding easy with its easy-to-operate features.
Especially the LOTOS MIG175 175AMP MIG Welder comes with almost everything that you need.
What do you look for in a welder? Reliability? Compatibility? Great field performance? Or something else? It has everything.
If you want to overlay the filler metal accurately, you need a stable and high-performing wire feeder.
The product offers you an aluminum wire feeder to meet the best welding experiences.
Includes Spool Gun:
Can you weld comfortably with a MIG welder without a spool gun? It's painfully tough.
To sort the problem out, LOTOS offers you a spool gun with the welding machine.
Besides, it includes a Torch, Argon Regulator, Gas Hose, welding musk, Wire, and so on.
Not only the Aluminum, but you can also weld mild steel, stainless steel, and other metals as well with this welder.
So, you don't need to spend an extra penny to weld several materials.
Things you need to consider before buying an Aluminum Welder
You cannot beat about the bush when it comes to purchasing such mechanical stuff.
You must have a clear idea about the features and attributes of it. Otherwise, you cannot meet the one that you need.
Let's have a glance on the things that you need to consider-
Consider the thickness of metal as the potential are not the same as all welders.
But how thick the welder should be to weld?
According to the experts, you should allow approximately 30 amps of current for 1mm of Aluminum.
Alternatively, to melt 0.001 inches of Aluminum, you will need 1 amp of power.
If you still do not understand the math, more straightforwardly, you will need approximately 200 amps of current to weld a 1/8 inches of Aluminum.
The factor that you should pay heed to the most is the duty cycle of a welding machine.
It specified the temperature control of welder that helps to avoid overheating the device and keeps you hassles-free during the operation.
In other words, it will indicate how much time you can operate your welder before to rest.
For example, if your welder has 30% of the duty cycle, you can operate this continuously for 3 minutes.
Before get going for another start, it requires at least 7 minutes of rest. The percentage is calculated at 10 minutes of the period.
You may have a question out there. Why am I putting so much emphasis on the duty cycle?
If you operate the welder longer than the particular time, it gets heated up and melts the electric circuits.
AC or DC operation
Before going to any technical explanation, you need to know what the AC and DC stand for.
AC means Alternating Current, where the electric charge changes the direction periodically.
But in Direct Current (DC), the electric charge flows in only one direction.
But which one is preferable for an aluminum welder?
According to specialists, AC is more compatible compared to DC.
Because in DC, there has occurred the cathode cleaning, which is actively responsible for increasing the temperature significantly?
As a result of the electrode, even such refractory metal like Tungsten electrode begins to break down.
Overheat can cause severe damage, especially when you are dealing with thin metals.
It's tough to check the heat manually even if you are experienced enough.
Considering a welder with pulse welding is always a great idea. Pulse welding maintains the power switching the full power current to low power current. So, It reduces the risk of metal deformation.
So, consider the feature as compulsory
The product should get paid what it requires. Of course, you can't expect a bunch of great features with some penny.
But at the same time, there have such some products that don't worth the price. So, you have to be very clear about what you are going to pay
How To Weld Aluminum (TIG and MIG)?
Now, you need to know about how to weld aluminum with TIG and MIG. So that you can know about your expertise.
We're going to Provide you as much as information about TIG and MIG, which help you to choose your welder.
Check this out...
MIG Welding Process For Aluminum
When you are going to deal with a MIG welder, there are several things that you should pay heed to. Let's have a birds-eye look at them-
Avoid Thin Aluminum Sheet:
Consider the thickness while using a MIG welder. As the process contains a high power supply, the thin sheets might get melt.
So, Apply the process when you are welding at least a 14 gauge sheet.
How would you hold your torch? If you don't want to have a messy finishing, you have to be very calculative while holding the torch.
A 10-15 degree angle will be appropriate for a smooth finish.
If you want to avoid the Aluminum wire getting jammed and complete the task fast, use a spool gun at your MIG. It will make your job easy and more productive.
Clean before welding...
Use acetone and likely solvents to clean the metal. But if you need to weld lots of metal, you can grind them as well considering the cost.
Straight to the Argon:
Which gas to use? You already know the answer. Argon is an ideal choice, especially for the MIG welding process.
Though you can use a mixture of some gas also, Argon is the most practiced one.
TIG Welding Process For Aluminum
The TIG welding process is comparatively more compatible with thinner sheet aluminum welding. You need to consider the following things below -
Clean the Metal before Welding...
The oxide layer, generated on the metal, create critical issues while welding. Operators, who are new in this business, maybe unaware of the issues regarding cleaning.
You will see a huge difference in melting points between Aluminum oxide and base material.
The melting points of Aluminum Oxide are approximately three times higher than the base material.
Clean the layer with a carbide cutter or stainless steel brush before welding.
But, remember, the oxide has a powerful reforming power. So, weld immediately after the cleaning process.
If you want a smooth and shapely finish, you must have the proper balance control and the balance control is all about a compatible percentage of EN and EP cycle. EN considered as welding side, where EP works as an oxide removal feature.
Though the older welder had a balanced 50/50 EN, EP ratio, the modern machines allow you to change it according to your requirements.
So, recognize what balance do you need.
Maintaining proper amperage is another key point. In the traditional TIG process, amperage often controls with a fingertip or foot pedal control.
But setting the maximum compatible amperage is more effective.
But the question is,
what is the adequate amperage for aluminum Tig welding?
The rule of thumb allows 1 amp of current for every 0.001 metal thicknesses.
Now you can easily calculate how much your targeted material requires.
So What's The Verdict...
Hey, congratulations. I hope you have got your expected one. These 6 products are leading the market now.
The credit of this achievement goes to their attractive and compatible features that meet the key requirements of the customer.
Besides, the experts love these products because of practical performance. Many manufacturers have done alluring marketing with their products.
They claim, their products can do that, this and that. But when you operate it, you realize that the whole thing was shoe off. And it's already too late to regret if you have made a mistake.
But the following welders are something else. They are committed to giving you everything that you need. They have satisfied many consumers with their performance. Now, it's your turn.