Professional TIG welding for aluminum including sheet metal, plate, pipe, and custom fabrications. Low distortion, full penetration, and leak-proof results. Certified welders.

Why Aluminum Requires TIG?

To understand why TIG welding for aluminum is the preferred process, you must first understand aluminum metallurgy. Aluminum forms an aluminum oxide layer instantly when exposed to air. This oxide melts at over 3700°F, while the base metal melts near 1200°F. If you try to weld aluminum without TIG welding for aluminum, the base metal melts first and flows away, leaving a weak, contaminated joint.

AC TIG welding for aluminum solves this problem. The alternating current reverses polarity 120 times per second. During the electrode positive portion of the cycle, the arc blasts the oxide layer off the surface — a cleaning action unique to TIG welding for aluminum. During the electrode negative portion, it heats the base metal. This self-cleaning action is what makes TIG welding for aluminum so effective.

Our TIG welding for aluminum process also benefits from precise amperage control via foot pedal. When performing TIG welding for aluminum, the welder can start at low amperage to establish a puddle, then increase heat as needed, and back off instantly when approaching an edge or completing a pass. This level of control in TIG welding for aluminum is impossible with MIG or stick welding.

Additionally, TIG welding for aluminum produces no spatter. Spatter from MIG embeds in the aluminum surface, creates corrosion points, and requires tedious cleanup. TIG welding for aluminum leaves a clean bead that is ready for anodizing or powder coating with minimal post-weld treatment. That is why professionals choose TIG welding for aluminum for critical applications.

Material Thicknesses We Weld:

Our TIG welding for aluminum service covers a wide thickness range.

0.040 to 0.063 inches (18 to 16 gauge) – Lightweight enclosures, ductwork, and decorative panels. We weld at 35 to 60 amps with 1/16 inch 4043 filler. Copper backing bars prevent burn-through.

0.080 to 0.125 inches (14 to 12 gauge) – Automotive panels, small fuel tanks, and equipment guards. Parameters range from 60 to 90 amps with 1/16 or 3/32 inch filler.

0.160 to 0.250 inches (8 gauge to 1/4 inch) – Marine components, structural brackets, and heavy enclosures. We weld at 90 to 150 amps with 3/32 inch filler.

0.313 to 0.500 inches (5/16 to 1/2 inch) – Structural frames, mounting plates, and machinery components. Multi-pass technique with 1/8 inch filler at 150 to 220 amps.

0.500 to 1.000 inch – Heavy plate for industrial equipment. We use preheating to 200°F and 3 to 5 weld passes depending on thickness.

For each thickness, our TIG welding for aluminum procedure specifies exact parameters, filler alloy, and pass sequence.

Aluminum Alloys We Weld:

Different alloys require different filler metals and techniques.

1100 – Commercially pure aluminum. Very soft and formable. Used for chemical equipment. Use 1100 or 4043 filler.

3003 – General purpose alloy. Excellent formability. Common for fuel tanks and ductwork. Use 4043 filler.

5052 – Marine grade with excellent corrosion resistance. Higher strength than 3003. Use 5356 filler for best corrosion resistance.

5083 – High strength marine alloy. Used for boat hulls and heavy fuel tanks. Use 5356 filler.

6061 – Most common structural alloy. Good strength and weldability. Use 4043 for general work or 5356 for higher shear strength.

6063 – Extrusion alloy. Used for pipe, tubing, and architectural shapes. Use 4043 filler.

Our TIG welding for aluminum technicians select filler metal based on base alloy, service environment, and post-weld treatment requirements.

Joint Types and Preparation:

Proper joint design is essential for strong welds.

Butt Joints – Two pieces edge to edge. For material under 1/8 inch, leave a gap of half the thickness. Use a copper backing bar. For thicker material, add a 30 to 45 degree bevel on each side.

Corner Joints – Two pieces meeting at 90 degrees. Outside fillet welds are easiest. Inside corner welds require good torch access.

Lap Joints – Overlapping pieces. Weld from the top side only. Minimum overlap is 3 times the thinner material thickness.

T Joints – One piece perpendicular to another. Bevel the vertical piece when thickness exceeds 3/16 inch.

Edge Joints – Two pieces flat against each other. Weld along the top edge only.

For every TIG welding for aluminum project, we clean the joint area with acetone followed by a stainless steel brush used only for aluminum. Cleaning is performed immediately before welding because oxide reforms within hours.

Distortion Control Methods:

Aluminum expands roughly twice as much as steel per degree of temperature rise. Without control, a 36 inch panel can bow by 1/2 inch or more.

Our TIG welding for aluminum process includes several distortion control strategies.

Backstep Welding – Weld 1 to 2 inch segments in reverse order along the joint. This distributes heat more evenly than continuous welding.

Strongback Fixturing – Our fixture tables have slotted holes that allow lateral expansion while preventing out-of-plane distortion.

Chill Bars – Copper or aluminum blocks placed behind the weld zone extract excess heat. For long seams, we use water-cooled chill bars.

Pulsed TIG – Our machines offer pulsing capability. A 50 percent background current reduces total heat input by up to 40 percent.

Interpass Cooling – Between weld passes, we cool the part with compressed air until it reaches room temperature.

Weld Sequence Planning – For large assemblies, we weld opposing sides alternately to balance thermal contraction.

Using these methods, we hold flatness to within 1/32 inch per foot for most TIG welding for aluminum work.

Surface Preparation and Cleanliness:

Aluminum oxide is the enemy of good welding. Our cleaning process removes it completely.

Step 1 – Degreasing – We wipe the weld zone with acetone. This removes oils, fingerprints, and cutting fluids.

Step 2 – Mechanical Abrasion – A stainless steel brush dedicated to aluminum removes the oxide layer. We brush in one direction only to avoid embedding contamination.

Step 3 – Final Wipe – A clean lint-free cloth with acetone removes any remaining particles.

Step 4 – Immediate Welding – We weld within 4 hours of cleaning. After 4 hours, the oxide layer begins to reform.

We also ensure that grinding wheels, brushes, and other tools have never touched steel. Cross contamination introduces iron particles, which cause galvanic corrosion and contaminate the weld pool.

For TIG welding for aluminum that requires the highest quality, we also offer chemical cleaning using a mild caustic solution followed by nitric acid rinse. This removes all oxides without mechanical abrasion.

Quality Inspection Methods:

Every TIG welding for aluminum project receives inspection appropriate to the application.

Inspección visual – All welds are examined for cracks, porosity, undercut, incomplete fusion, and surface appearance.

Dimensional Inspection – We verify flatness, squareness, hole locations, and overall dimensions against your drawing.

Dye Penetrant Testing – Reveals surface cracks invisible to the naked eye. Used for structural and pressure-containing applications.

Bend Testing – A sample coupon is bent 180 degrees. No cracks are permitted. Performed on first article for new weld procedures.

Radiographic Testing – X-ray inspection reveals internal lack of fusion and porosity. Required for aerospace and pressure vessel work.

Ultrasonic Testing – For plate over 1/2 inch thick. Measures fusion at the root face and detects internal flaws.

Leak Testing – For tanks and sealed enclosures, we perform water immersion testing or helium leak detection.

We retain all inspection records for a minimum of 7 years. Certified test reports are available for an additional fee.

Common Applications:

Our TIG welding for aluminum service supports many industries.

Automotive – Custom body panels, battery enclosures, heat shields, intake tubes, intercooler piping, and race car components.

Marine – Fuel tanks, water tanks, deck plates, hatch covers, T-tops, radar arches, and custom brackets. Saltwater environments demand 5356 filler.

Aerospace – Ducting, instrument panels, access covers, and prototype components. Our work meets AS9100 requirements.

Architectural – Stair railings, curtain wall panels, light fixtures, signage, and decorative screens. Cosmetic appearance is critical.

Industrial – Machine guards, equipment enclosures, conveyor components, and structural frames.

Food Equipment – Stainless steel alternative for non-magnetic requirements. Smooth welds prevent bacterial growth.

For each industry, we adjust cleaning protocols, welding parameters, and inspection standards accordingly.

Post-Weld Services:

Welding is often only part of the story. We offer additional services to complete your project.

Post-Weld Heat Treatment – For 6061 structures, we offer T6 solution heat treatment and artificial aging. This restores strength lost in the heat affected zone.

Straightening – For parts with minor distortion, we use hydraulic presses and straightening fixtures to restore flatness.

Surface Finishing – Abrasive blasting, chemical brightening, mechanical polishing, and powder coating.

CNC Trimming – Post-weld machining of mounting holes, edges, and sealing grooves.

Assembly – We can install hardware, attach brackets, and perform sub-assembly work.

Our TIG welding for aluminum service includes coordination with these post-weld processes to ensure smooth project flow.