10 "Rules of the Road" for TIG Welding Aluminum
RULE #1. Only weld aluminum that is clean enough (new aluminum is often clean enough. Dirty aluminum needs cleaning)
RULE #2. Use the right filler rod…3/32” 4043 or 5356 filler rod is a good start
Washington Alloys Aluminum Filler Metal Chart
RULE #3. Make sure your tig torch is plugged in to correct dinse plug in (usually the dinse labeled EN or - with the TIG torch icon but read the manual to be sure)
RULE #4. Use AC current with AC balance set for just enough cleaning action (usually about 1/8” of frosty etching outside the bead)
RULE #5. Set AC Frequency to 60-100 hz when learning. Experiment with higher frequency settings later.
RULE #6. BIG cups don't work well on Aluminum. Use a #5 thru #8 cup. A #6 gas lens is a great all around cup and a #7 clear cup helps if see better.
RULE #7. Use enough argon flow but not too much. 2-3 CFH per cup size usually works but test it on scrap to learn the best flow rate
RULE #8. A 3/32” 2% lanthanated, E3, or LayZr tapered tungsten all will be fine for learning and are all usually good up to around 200 amps. If you need to weld thinner than .063” a 1/16” tungsten will work better, thicker than 3/16”, a 1/8” will work better
RULE #9. When using a foot pedal, Set machine amps to around 1.5 X metal thickness… example: 0.100” = 100 thousandths X 1.5 = 150 amps. You won’t always need all those amps but aluminum often needs more heat at first…Use foot pedal if ( or torch amp control) to control amps while welding.
