Aluminum Gas Welding Compared to Welding Steel Using the Gas Tungsten Arc Process

Aluminum gas welding can be accomplished with gas tungsten arc welding (GTAW) and it can also be used to weld steel, as well as other metals. GTAW is also called tungsten inert gas (tig) welding. Welding steel is one of the easier jobs when using rig welding, but there are a number of factors, which make it much harder to weld aluminum.

From cleanliness, arc length, machine settings, welding with a dirty tungsten electrode, filler rod angle, type of electrode, torch angle and size of electrode - you have to be extra-careful with all of these factors when you tig weld aluminum.

Here we go over these factors and how you have to be much more careful with aluminum than with steel.

- Make sure that the settings for your machine are correct. Set your machine to use alternating current and the high frequency switch should be at continuous mode otherwise it will make the arc stutter.

- A piece or object of aluminum left outside is likely to be highly oxidized after having come in contact with the elements. That should be weld only after thoroughly cleaning it - otherwise it will burn or weld extremely fast.

- Arc length - it is important to keep the arc at just the correct length. Arc lengths too long or too short, both should be avoided with aluminum. Too short the length, you your metal will jump on your electrode, damaging that and you. Too long a length and the heat will not be pinpointed enough to be of proper use.

- Keep your electrode clean. A dirty electrode will make the weld sooty - taking any fun out of the job you may have been having.

- Do not use pure tungsten electrodes with the new types of tig inverters to weld aluminum. The old types could use them, but not these new ones.

- You should keep the 1/16", 3/32" and 1/8" sized tungsten electrodes within easy reach when working with aluminum. With steel it is one size fits all policy, where you can go with a 3/32" tungsten for most of the jobs. But with aluminum, you need different electrodes depending on the thickness of the aluminum.

Aluminum gas welding just needs to be done with more care than other types of welding. Keep all these factors in mind and you will have your boat repaired or your ladder fixed in the best possible manner.