Best Practices for TIG Welding Aluminum

Author: admin / 2023-06-29

Creating high-quality TIG (tungsten inert gas) welds requires more skill than MIG welding, but there are some best practices that can help any operation get the most out of this process. Choosing the right filler rod and dialing in your welder settings are key to creating strong, aesthetically-pleasing welds.

TIG welding is more complicated than MIG welding because you must feed the puddle with a handheld rod rather than an electrode. These filler metals, or arc rods, come in a variety of diameters, alloys and packages. Getting the right combination for your job can be overwhelming, but there are some guidelines to follow that will allow you to choose the best TIG rod for the job.

The size of the TIG rod should match the thickness of the base material being welded. A rod that is too large can chill the puddle, making it difficult to achieve a smooth, consistent bead. In addition, using a larger diameter rod on aluminum can cause the weld to become brittle due to high thermal cycles.

If you are using the same base material for all of your TIG welding jobs, you can save time by selecting a rod with a standard diameter that will work on all types of stock thicknesses. This will reduce the number of different sizes you need to carry in your shop, and it will also help improve productivity by allowing you to complete jobs more quickly.

When selecting a TIG rod for an aluminum application, it is important to consider the alloy and type. ER4043 and ER5356 are both commonly used TIG welding rods for aluminum, but they differ in their alloy compositions and tensile strengths. ER4043 is an aluminum-magnesium binary alloy that is used for general purpose welding, while ER5356 is a high-performance rod that has a higher magnesium content and is heat-treatable.

Having the proper TIG machine setup is also critical for TIG welding aluminum. Make sure the machine is sized properly so that it can provide enough amperage for the application without running out of power. Also, be sure to use the proper shielding gases, as argon is typically recommended.

While the TIG welding process can be challenging, it offers many advantages over other welding methods. Using the right equipment, technique and filler rod for your aluminum applications can produce high-quality welds that are both strong and aesthetically pleasing. By following these tips, you can create the best TIG welds possible for your projects. To learn more about these topics, please visit our TIG welding page or contact us for a free consultation. We can discuss your needs and recommend the perfect TIG welding equipment for your business. We look forward to hearing from you.