Best Aluminium TIG Welder

By Delphine •  Updated: 05/16/22 •  11 min read
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Looking for the best aluminium TIG welder? Then, keep reading because we’ve put together every bit of information you need to know about welding aluminium and the best TIG welders for aluminium on the market. 

There are different methods of welding aluminium including MIG, oxy-hydrogen, TIG and many more but our main focus in this article will be TIG (Tungsten Inert Gas).

 

Why TIG welding for aluminium?

TIG welding produces weld with the use of a non-consumable tungsten electrode and as such it produces a high level of heat which leaves a high quality finish. 

It is best to use a TIG welder running on AC for welding aluminium since it has a low melting point and a high conductivity and this will leave you with some wonderful results.

 

Factors to consider when buying a TIG welder for aluminium

 

Portability

This is very important here especially if you’re going to use the unit for both domestic and commercial purposes, you’ll need to move it from your workplace to your home or the other way round. For that you’ll need one that is portable. 

If you’re considering a unit that is multi-purpose, then be ready to get one that is not so portable.

 

Power

For aluminum, you need a unit that has more power because aluminum has a low melting point and high conductivity. 

You should also check for a unit whose amperage can be adjusted easily. A unit whose amperage can be adjusted between 5 amps and 230 amps is ideal.

Read: Best TIG Welder For Beginners

Ergonomics and controls

You should purchase a unit that is easy to use and has adjustable controls. 

Welding aluminum is already a difficult task on its own and you don’t want to add the struggles of not being not being able to control the torch or even change it to that. If you’re a novice, you definitely need to get a unit which is easy to use and adjust.

 

Accessories

Some units come with extra accessories so you don’t have to buy them differently. You should purchase one that comes with accessories like face masks, cables, floor clamps and foot pedals.

 

Space and size

Before you purchase a welder, you should know how much space you have. Make sure you have enough space in your workshop to accommodate the unit and every other equipment you’ll use alongside it.

 You can purchase a cart to keep them all in, which will even make your workspace tidy and organized.

 

Input and output power

 You’re going to weld aluminum so you definitely need to know the input and output power of the unit you purchase. The output power depends on the input power. 

It is best to purchase a unit with 240 volts input power because only 140 amps is output by 120 volts units and that is insufficient for welding aluminum.

 

 

Reviews of the best TIG welders for welding aluminium 2022

 

Weldpro 200 Amp Inverter Multi-Process Welder

 As the name implies, this unit is multi-process and can be used for more than just TIG welding. It can be used for MIG and Stick welding as well.

It comes with a TIG torch and a lift arc TIG feature. It is portable as compared to other inverter welders and comes with a handle which makes it even easier to carry around.

It uses silicon-based technology in operating. It does not consume much power like a traditional inverter welder will do.

It uses digital controls and uses both AC and DC to weld so you can weld other materials other than aluminium.

Even though it comes with a foot pedal, you don’t have to worry about adjusting the amperage with it because it has its amperage control settings on its front side. When in AC mode it has a duty cycle of 40% at 240 volts and in DC mode, its duty cycle is 60% at 240 volts. It comes with a 2-year warranty.

Pros
  • Pocket friendly
  • Produces a fine quality result
  • Extra accessories
  • Can be used for other welding processes
  • Good duty cycle
  • Easy to use
Cons
  • Does not come with a foot pedal

 

 

Lincoln Electric Square Wave TIG 200

 Using the Lincoln 200 for aluminum leaves you with a quality finish that you’ll love. 

This is because it utilizes pulse width modulation for the AC process which has a filler metal deposition of great quality. It runs on both AC and DC and has a dual input of 120 volts and 240 volts and a 40% duty cycle at 240 volts and 25% at 120 volts.

It is impact resistant and built with high quality materials which will make it last for a long time. It comes with a range of accessories including a foot pedal, TIG torch, a 10 foot hose and a gas regulator. It is portable, weighing only 46.5 pounds and can be moved around easily.

 The voltage of the unit can be adjusted to fit the thickness of the material being welded. It is affordable and an ideal choice for home welders, beginners and DIY enthusiasts.

Pros
  • Budget friendly
  • Lasts long
  • Comes with accessories
  • Voltage can be adjusted
  • Easy to use
  • Friendly user interface
  • Produces a quality result
Cons
  • Duty cycle is not impressive

 

Hobart 500559 Handler Welder

The Hobart Handler is renowned for its ability to operate at all levels, even industrial.

This equipment can assist you with any domestic project. It is ideal for welding aluminium, steel, stainless steel, and other lighter metals. It runs on 115V household current. It has a 20% duty cycle at 90 Amps and can operate at up to 140 Amps. It weighs 57 pounds.

It’s also quite simple to set up and comes with a range of extras. This includes a clamp, power cord, dual-gauge regulator with gas hose, 030 inch contact tips, quick select drive roll, sample spool of flux-cored wire and material thickness gauge.

It has a 5-year limited warranty.

 

Pros
  • High adaptability in terms of welding materials and applications
  • Extras galore
  • Integrated storage
  • Setup and use are simple
  • Great for welding aluminium
Cons
  • Not portable
  • No safety equipment

 

 

Miller Electric MaxStar STR 210 TIG Welder

One of the newest additions to the Miller TIG welding collection is the Miller Electric Maxstar STR 210 TIG Welder with High Frequency Lift Start.

The MaxStar has a backup power button on it’s front panel that allows the machine to go to sleep while it is not welding, saving power.

It has a multi-voltage auto-line input, A memory card slot allows you to transfer settings from one machine to another and a duty cycle of 100% at 175 amps.

The TIG Pro-Set system from Miller has manufacturing presets to help you get things done quickly. The Miller Maxstar STRb210 TIG Welder may be adjusted from 300 feet away thanks to the wireless remote.

It has a 3-year warranty.

 

Pros
  • At 175 amps, there is 100% duty cycle
  • Memory settings make it simple to operate
  • 10 amp low end welds thin sheet metal
  • High frequency start
  • Quality welds
  • Portable
  • 3-year warranty
Cons
  • Does not accept AC
  • TIG torch not included

 

Primeweld TIG 225X

The PrimeWeld TIG 225X AC/DC TIG welder is a robust welding tool. It can be used to weld aluminum and provide high-quality results.

The welder includes a CK Worldwide 17 Series Superflex TIG Torch with Flex Head and accessories, as well as a TIG/stick selector switch, 2T/4T, and AC/DC polarity adjustment option.

This AC/DC 225 amperes TIG welder can be used to weld metals up to 12 inches thick.

The pulse function on the PrimeWeld TIG 225X is ideal for welding aluminum, stainless steel, and thin metals. In addition, it has a high frequency (HF) start, remote current control (foot pedal), and modern inverter technology with Modulation of pulse width.

Pros
  • Amperage control via foot pedal
  • Can be used for both TIG and stick
  • Accepts AC and DC
  • Dual voltage
  • High-frequency start
Cons
  • Over a lengthy period of time, the system performance is uncertain

 

Cleaning aluminium before welding

Do you know that you have to clean aluminium before welding? 

Well, that’s the first thing you have to do before welding aluminium.

To you, it might look clean but there might be grease and oxides which can’t be seen with the naked eye. 

In cleaning aluminium, there are two main steps; removal of grease and removal of oxides.

 

Grease removal

 In order to get rid of all the grease on the surface of aluminium, you must use a degreaser.

 There are two main types of degreasers you can use; mild alkaline solutions and organic solvents. Organic solvents like vinegar could be used while mild alkaline solutions like methyl ethyl, lacquer and acetone could be used. 

Clean the surface of the aluminium with the solvent of your choice and a lint-free tag. Do not use a shop rag or a wire brush as it would just spread the grease over the surface of the metal. 

Read: Best TIG Welder For Home Use

Oxide removal

After the grease has been removed, the next step is to remove oxides. Under this step, there are two methods; using a strong alkaline solution or using a wire brush.

 You can spray the alkaline solution onto the metal surface or immerse the entire workpiece in the solution.

Be careful when using such solutions because they are normally phosphoric-based or may contain hydrofluoric acid which may be harmful. With the use of a wire brush, you can scrape off any oxide on the surface of the aluminum. Use a clean brush which has soft bristles for a perfect finish.

After cleaning has been done, you can proceed to welding only after the aluminum surface is perfectly dried out. Do not leave it for too long as it may become contaminated again.

 

Some tips on how to weld aluminium

 

Wear all protective clothing to prevent burns.

 

Carefully set the AC amperage and ensure you use the right amperage.

 

The AC output frequency must be set right.

 

To get the best results, set the polarity right.

 

To get the ideal stacked-dimes look, use the right amount of filler metal.

 

Ensure that the balance control of the welder is well adjusted.

 

FAQs 

 

Can I weld steel to aluminium?

Special techniques are required to weld steel to aluminium as such, if you don’t have a high level of expertise, it’ll be difficult to do so.

 

Can I weld aluminium with DC? 

If you’re ready for the struggle, yes, it’s possible to weld aluminum with DC but it’s better to use AC because it melts the oxides that inhibit weld quality.

Read: Best TIG Welder Under $500

To conclude,

We are sure you are now certain on which welder to purchase for welding aluminum.

Remember to clean your aluminum workpiece thoroughly before welding to get the best results. Purchase a unit that comes with extra accessories so you don’t have to pay extra to acquire them. 

We hope you enjoy working on your project and we wish you all the best!

 

 

 

 

 

Delphine