Complete Guide to weld Aluminum (TIG, Mig, Stick & Flux-Core) – 2020

Aluminum Welding

Are you in the welding industry?

Looking for a special guide to know, and improve your abilities and knowledge about aluminum welding to grow in this competitive, and growth-friendly industry or want to be a top-class executive of any of these aluminum welding companies.

Then here we are with all the information you need. You will get the answer of how to weld Aluminum TIG, Mig, Stick & Flux-Core, and also can do them in person.

Aluminum welding is easy if you weld carefully. It doesn't matter what welder you are using TIG or MIG or Stick. You just have to do some practice and then you can be a master of it. 

So, are you ready for this existing journey?

I hope, you are. Let’s start.

How to weld Aluminum (TIG, Mig, Stick & Flux-Core)?

TIG Welding Aluminum:

Tig stands for Tungsten Inort Gas welding; it uses a tungsten electrode that has a high melting point.

In the welding industry, controlling the temperature is a big deal, and it can be done through the foot/ thumbwheel.

Moreover, its usages AC current, and the electrode the tig emits usually turns out positive.

All these are the initial information. We will know about the details that we need for our daily work in our upcoming words.

Amperage Settings:

Amperage settings depend on the type of metal we are using, in terms of us- Aluminum, and the thickness of that specific sheet.

We are providing a few best settings for your work:

Amperage Settings for TIG Welding Aluminum

Tungsten Electrode Selection:

Are you out looking for Best TIG Tungsten For Aluminum?

But confused about what you should consider before picking one up?

Thoriated electrodes are one of the most popular ones out there but some metals are comfortable with other electrodes.

As we are talking about aluminum, so, whatever electrode can do well in AC current, we will go with that.

Here are a few suggestions:

  1. 2% Lanthanated (Blue) 3/32” × 7” Tungsten Electrode
  2. Pure Tungsten 3/32” × 7” Electrode
  3. 0.8% Zirconiated (White) 1/8” × 7” Tungsten Electrode

We’ve chosen these 3 because these one works with AC better, and can provide the best service that you want.

Remember one thing, in aluminum welding, you will always need AC current.


  1. TIG is so optimized and utilizes less amperage.
  2. It can produce great welding on thick & thin metal bars
  3. It has a lower amperage, and foot machine that allows change amperage dynamically. according to work.
  4. It’s small and can be used anywhere in any use.
  5. It uses the helium, argon combination what is best for aluminum.


  1. It has a low filler deposition rate & respectively slower than others.
  2. Highly skilled men are required for handling TIG welding.
  3. Because of its size, it occurs with a safety issue because users are exposed to its high-intensity lights. 
  4. It can’t be used thick aluminum sheets.

MIG Welding Aluminum:

MIG stands for Metal Insert Gas welding; It uses gas mixture or insert gas. Those are typically Helium & Argon.

In the welding industry, Time is money; and its high-quality welds can be produced faster than its competitors.

Moreover, its usages DC & AC current, but AC is cheap. All these are the initial information.

We will know about the details that we need for our daily work in our upcoming words.

Amperage Settings:

Amperage Settings for MIG Welding Aluminum

Mig Wire Selection:

Reading manuals before choosing anything is always a good thing to go with.

But we are here a bit advance guide for the suitable wire to use what will directly affect your result & setting on MIG.

We have to know a basic equation before selecting that material thickness determines amperage, and a 0.001-inch metal sheet requires the output of 1amp.

So, based on this equation or common principle, we are suggesting 5 commonly used wires with their amperage outputs:

  1. 30- 130 amps: 0.023 inch
  2. 40- 145 amps: 0.030 inch
  3. 50- 180 amps: 0.035 inch
  4. 75- 250 amps: 0.045 inch  


  1. It has the faster-producing capability
  2. There is no kind of flux in use, so, the great quality product is assured every time.
  3. It uses gas shields that protect the arc. SO, there is a little possibility of losing alloying elements.
  4. MIG process is flexible, and it can be operated in semi and fully automatic.
  5. MIG Process can be used with various metal alloys including Aluminum.


  1. It produces much more heat than others, so, its losses the flexibility of using it in vertical & overhead welding positions.
  2. The complex setup makes it harder to handle.

Stick Welding Aluminum:

Are you working with rusty aluminum?

But you badly need to weld it.

Are you thinking about the options?

Then don’t worry, you have stick welding. It’s highly economical and can work with thick, and rusty aluminum.  

So, are you wanting more details? Go through the next section, you will get whatever you need.

Amperage Settings:

Amperage Settings for Stick Welding Aluminum

Electrode Selection:

Electrode selection is one of the critical choices of the work because it’ll directly affect the quality of the work. 

Moreover, it also indicates how efficient the work will be. The electrode selection depends on the thickness of your aluminum sheet.

However, we mentioned the list in the amperage setting, but here we will tell you how to understand.

Here is an example of an electrode name: EXXYZ/ E6010

Here, it means an indication of an electrode for welding. The first 2-3 digits indicate the strengths in 1000 pound/ square inch of metal. 3rd digit indicates the position- 1 for all position, 2 for horizontal/ flat position, 3 for any flat position. The last & the 4th position is a type of power supply you should use.

We can find out what we need now.

Let’s go through the test, and tell us about what the number E6020 means?

If your answers are kind of like this- this is an electrode having the strength of 60000 psi with having the ability to use in any flat/ horizontal position with DC current then congrats, you are doing well.


  1. When you have rainy weather, or more or less windy then this stick welding can be proved most effective.
  2.  It’s a budget-friendly build.
  3. You don’t have to use an external shielding gas, so, it’s a big go for saving money.
  4. Changing rods is kind of easy here.
  5. A few attachments are available for making your work more efficient.  


  1. It’s kind of a slow process based
  2. It’s not beginner-friendly, so, taking experts to help to get a grip of it is suggested from the beginning.
  3. It shows difficulties with the thinner metals.
  4. Welding roads are needed to be changed more oftentimes.

Flux Core Welding Aluminum:

Flux Core Welding is a gasless welding process, and most efficient for beginners for the easy learning curve.

A new owner can get a grip of within few days, and we are here to suggest them the best amperage settings, best flux core wire to selecting, and all the advantages, and disadvantages of this and will make you expert in no time.

Amperage Settings:

Amperage Settings for Flux Welding Aluminum

Flux Core Wire Selection:

Choosing wires for a flux core is a crucial part because it’s a gasless process and this wire act as an essential part of the workflow.

The wires are suggested based on the different situation you will go through in real life, and when you want to provide the best quality product.

Here are a few wires: 

  1. E71T-1 (FCAW-G): It has the highest deposition rates out of position.
  2. E71T-8 (FCAW-S): I gain the highest deposition rates without shielding gas.
  3. E70T-5 (FCAW-G): It has the fastest way to weld hard to weld steels.


  1. It’s a core based, so, you can get a different kind of experience, and can be the best option who want to avoid the gas.
  2. It uses wires instead of using gas, which is more, stable & user friendly to tough welding.
  3. It can achieve greater penetration.
  4. It’s a beginner-friendly environment, so, a professional with little knowledge can achieve more out of it.


  1. It’s kind of messy to work with, because you will get the by-product, but won’t go to have the gas for suppressing it.
  2. It’s occasionally slower than MIG.
  3. I can be more expensive than other alternatives.
  4. It has reduced transfer efficiency.
  5. Thinner welds are a bit difficult to achieve with it.

5 Additional Tips before Welding:

A few additional tips can make your welding experience safer and efficient.

We will suggest you go through it for making you professional in your work. So, what are you thinking?

Let’s jump into the tips & tricks.

Knowing about the Correct Specs for the Job and Your Equipment:

You always have to know about the best capability of your gas & wires. It could be argon, carbon dioxide, or a mix of mentioned two.

You always have to pick the right component based on metal & requirements you have given with.

You have to widen your area of research for getting the best result.

Picking the Right Rod Size for the Work:

Generally, the thickness matters the most in this case. The thickness of the rod should get along with the thickness of the metal.

You are not recommended to use a 1/8” rod on a thin/ weak piece of metal because it might not pick the result according to your desires, like putting an unwanted hole in the metal sheet.  

Remember to Extend Your Tungsten Electrode to the Suitable Length:

In TIG welding, positioning the tip of the electrode at the right length is an important part of getting the right product.

If the tip isn’t visible enough, then you won’t be going to do the right work.

If that tip extends too far, then you won’t be going to see the heat concentrating in the right place or aren’t focused, has the probability of melting external parts.

Personal Protective Equipment:

Personal Protective Equipment, aka PPE, is a daily friend in your work. It’ll protect you from the heat, spark, and other harmful elements. 

Wearing masks & glass can provide a few more protection. Wearing hand gloves specified to the works will protect your precious hands.

You will have to wear a few more equipment for protecting your other parts.

Check Your Ventilation:

For breathing clean air, proper ventilation is mandatory because life is important than anything & you should wear an approved respirator to protect your lungs.

If you face any problem related to ventilation, then stop doing that and search for a solution.

Final Verdict:

You have gone through the ultimate guide, and hopefully, find out what’s the best for your work.

We promised you to tell about How to weld Aluminum TIG, Mig, Stick & Flux-Core, and we fulfilled it with utmost accuracy.

Though this journey, you also have found out how to choose the best welder for aluminum according to its amp settings.

We are happy to provide this knowledge, and we will provide information like this in the future.

Stay with us, and grow like a pro.

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