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Welding aluminium: what you actually need

Aluminium is not steel with a different setting. Its oxide layer melts far hotter than the metal underneath, so TIG requires alternating current, and MIG requires wire that will feed without buckling. Everything else follows from those two facts.

Aluminium is not steel with a different setting. Its oxide layer melts far hotter than the metal underneath, so TIG requires alternating current, and MIG requires wire that will feed without buckling. Everything else follows from those two facts.

What we recommend, and why

  1. WELDINGER MEW 202 SYN puls dig

    200 A · pulse and double pulse · aluminium synergics · €600

    The only machine here with genuine pulse and a spool gun interface — which is what makes aluminium a normal job rather than a fight.

    Best for: Aluminium work, and anyone who wants the weld to look like the ones in the photographs

    ≈ 600 €

Questions people actually ask

Can I weld aluminium with a DC TIG machine?

No. Direct current cannot break the oxide layer, and no gas, tungsten or technique substitutes for it. This is the single hardest limit in welding, and it is why AC/DC machines cost more. If aluminium is anywhere in your plans, buy AC now — it cannot be added later.

Why does aluminium MIG wire jam?

Because it is soft. Steel wire is stiff enough to push four metres down a liner; aluminium compresses and coils behind the drive rollers. The fixes, in order: a spool gun with the spool in the handle, a Teflon liner with U-groove rollers, or a very short torch.

Prices quoted in these summaries are dated readings. The live price is shown next to each product.

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