Even if you are an expert, finishing a welding job can be very challenging. Welding aluminum metal is especially complex because of its unique chemical structures, which require added effort and skill. When it comes to welding aluminum, the main issue is the burn through rate. You have to be extremely careful and skillful when you weld it. It would help if you kept in mind that you need to have better control and speed when you weld aluminum; otherwise, you will ruin your work. Having the best aluminum welding machine is crucial.
| PRODUCT | BRAND | EXPERT RATING | CHECK PRICE |
|---|---|---|---|
 | AHP Alpha TIG 200 Amp IGBT AC DC Tig/Stick Welder |  | Check Price |
 | Hobart Handler 210 MVP MIG Welder Dual-Voltage |  | Check Price |
 | Miller Electric - 951452 - MIG Welder, Millermatic 350P Aluminum Series | | Check Price |
Best aluminum welding machine–Facts Guide
What is the best aluminum welding machine? If you have a project that involves aluminum metal, you should know the three options below:
TIG welding
TIG Method of welding is the most used when it comes to welding aluminum. Aluminum is a type of metal that requires a lot of heat to be welded; it also requires a machine that gives sufficient control. Aluminum metal can retain heat for a long time, and TIG machines are good at keeping it under control to avoid overheating. If you know how to use this type of machine, you should avoid a burn through.
Furthermore, welding of this type can be used for thicker aluminum pieces and thinner ones such as sheets. Since a filler rod is required, the person who is maneuvering this machine must choose a separate welding rod and use an alloy close to the alloy of the pieces as much as possible.
If you want to weld aluminum in a different manner, you need to have at least some knowledge of the methods involved. TIG Is much more difficult than MIG type of welding, but the outcomes are more successful.
MIG welding
MIG welding is also an effective way to weld aluminum. When choosing the best aluminum welding machine, you should choose between either a pulse welding or spray arc welding method.
With the first option, you would need an inverter. The second one involves a constant voltage supported by a current machine.
Welding using the MIG method is better if you want to weld thinner aluminum pieces mostly because the heat is well distributed. When you select a shielding glass, 100% argan is recommended and is the best-known choice for MIG welding aluminum metal.
Torch welding
Another option is torch welding, but it is more complex then welding using the MIG or TIG Method. Experts may go for this option because they can control the heat much better on the metal, but for those who are just starting with torch welding, it is recommended that they stay away from this method and hone their skills first.
Burn throughs are much more likely to happen when you are using the torch welding method. To do this method well, you need to become dexterous and skillful.
Cleaning aluminum workpieces
The type of welder you choose to weld aluminum really doesn’t matter since you must clean each workpiece thoroughly before you begin. Aluminum oxide has a greater melting point than pure aluminum. If you leave out any oxide on the surface of the metal you’ll be working on; you may be challenged with issues such as oxide inclusion and weakened strength of the weld.
In many cases, aluminum pieces should be cleaned mechanically using a wire brush or a chemical etching process.
Keys to aluminum welding
In its pure form, aluminum is quite a soft metal with varied uses; however, it requires alloys to improve its strength. Since aluminum properties vary greatly from steel metal, working with aluminum can present some difficulties, such as distortion and sensitivity to heat. Despite these challenges welding aluminum using the MIG method is quite easy when using the best aluminum welding machine and following the right procedures.
Best aluminum welding machine–Tips
It should be noted that important factors below when using the MIG method should be applied
Material thickness
The thickness of the aluminum material that can be welded using MIG are 14 gauge and heavier. The output capacity of the welder will dictate the thickness you can weld. To weld aluminum that is thinner than 14-gauge, one option is to use a specialized pulsed MIG or AC TIG welding tool.
Keep it clean
Aluminum should be cleaned thoroughly before welding, and any lubricants from the material should be removed. The removal of oxides should be done after the degreasing process using a stainless-steel wire brush. If you are using a power wire brush, it is crucial to keep the RPMs and pressure at a low setting to reduce dirt on the material’s surface, which could trap oxide and impurities beneath the surface. Always clean the material with a wire brush meant for aluminum to avoid contaminating the base material.
The right gas
Since aluminum is a non-ferrous metal, it requires at least a hundred percent argon shielding glass. Flow rates of 20 to 30 cubic feet per hour are the recommended setting.
The right process
When welding aluminum using the MIG method, the best mode is spray transfer. Using this method gives a very smooth transfer of molten metal droplets from the electrode’s end towards the molten pool. The heated droplets crossing the arc are much smaller in diameter compared to the electrode. As a result, short-circuiting is avoided in spray transfer, and the rate of deposition and efficiency are much higher. However, it is crucial to note that spray transfer requires a huge amount of heat, which will create a large weld pool with enough penetration that might be difficult to manage. Spray transfer should not be used on metal thinner than 14 gauge.
Gun and wire feeding options
Choosing a gun and wire feeding system is a crucial step prior to MIG welding aluminum. Aluminum wire is commonly inserted with a spool gun or with a push-pull system. Spoon types improve the insertion of soft wires by targeting a small spool of wire on a pistol grip style gun. When you use a spool gun, it eliminates bird nesting chances because the wire is only inserted in a few inches. With a push-pull system, a motor in the gun pulls the wires through the liner while a motor on the feeder functions as an assist motor. This method is best when welding away from the power source and can be more comfortable and user friendly.
Filler metal
It is crucial to know the alloy of your base aluminum to know the exact conditions the finished material will undergo. Please consult your local welding distributor or aluminum filler metal consultants for their opinion on which wire alloys best fit your project.
Best aluminum welding machine–TIG Welding vs. MIG Welding
TIG method or tungsten inert gas and MIG method or inert metal gas are the two arc welding processes. These will have similarities and differences.
Electrode
TIG welding type uses a tungsten electrode that is not consumed during the welding process. MIG welding type uses a metal electrode, which also functions as filler material for the weld and is consumed in the welding process.
Shielding Gas
Argon as a shielding gas is used in MIG welding, but helium is occasionally substituted. Argon is also the most used shielding glass used in MIG welding, but argon mixtures and carbon dioxide are often used for other types of applications.
Filler Material
TIG welding type requires a separate filler in rod or wire because the electrode is not consumed in the welding process. The filler material is delivered through the electrode in the MIG welding process.
Work Piece Materials
The MIG method can be used in most metals from steel to aluminum and many others. The MIG welding process was created for non-ferrous metals but can also be used in steel.
Difficulty
The TIG welding process is considered to be more challenging than the MIG welding method because it requires tighter tolerances between the electrode, the filler rod, and the metal.
Three best aluminum welding machine
OUR TOP PICK!
OUR TOP PICK!
Product Name: AHP Alpha TIG 200 Amp IGBT AC DC Tig/Stick Welder
Product Description: This best aluminum welding machine is a professional level aluminum welder that comes at an affordable price point. It is your best go-to option when using the TIG method in welding. Hands down, this best aluminum welding machine is professional yet affordable. A notable feature of this professional-grade welder is its stick function, which gives you a great deal at a budget price. If you examine the quality of this best aluminum welding machine, the price is too good to be true. It has a reliable power source and state-of-the-art technology, which will ensure reliability and longer-lasting power. The inclusion of the pulse width modulation helps achieve an efficient performance using the power source.
Availability: InStock
-
Durability
-
Power
-
Attachments
Overall
Summary
This best aluminum welding machine comes with full features and gives control over the cleaning for ac. With exceptional performances in both the 110 voltages and 220 voltages, this best aluminum welding machine is one of the most versatile welders you can get at this price point and offers better control. The TIG best aluminum welding machine provides you the ease of use and better control with its unique foot pedal feature.
Pros
- precise welding of thinner materials
- includes a foot pedal for greater welding control
- 3-year warranty
Cons
- No negative reviews so far
Runners Up
Hobart Handler 210 MVP MIG Welder Dual-Voltage
If you are going for a MIG welder best aluminum welding machine, this brand is the best one out there on the market since many professional welders recommend it. Why is this best aluminum welding machine so well-regarded? One crucial factor is it allows switching powers with ease. If you need to switch between 115 voltages or 230 voltages, you don’t need additional tools since you can shift between them with just the flick of a switch.
This best aluminum welding machine comes with smart intelligence and automatically adjusts to the correct power options regardless of the source.
With the Hobart handler’s best aluminum welding machine, you can weld anything from body panels, trailer frames, farm equipment, racks, and even hitches. Setting this up is easy, and all you need to do is follow the instruction manual that comes with the equipment. It is good to know that it only takes a few minutes to get everything ready with this best aluminum welding machine and start the action.
Miller Electric - 951452 - MIG Welder, Millermatic 350P Aluminum Series
Consumers well regard the Millermatic aluminum series flux core best aluminum welding machine. It is considered to be the favorite of many consumers. However, this may not be ideal for heavy industrial welding. However, based on experience, this best aluminum welding machine provides enough features and power for a professional welder and DIY enthusiast.
This best aluminum welding machine has a welding formula which is not only sufficient for household. It is also farming, and do it yourself projects. Artists who use this best aluminum welding machine are contented with their efficiency. It should also be noted that this product comes with additional attachments.
You only need to read the instruction manual of this best aluminum welding machine to discover each attachment’s proper use. The smart configuration is also bound to give you possibilities even though it is not the slimmest option out there. Storing this best aluminum welding machine wouldn’t be too difficult. It only measures 34 inches in height and 19 inches in width.
The material thickness of this best aluminum welding machine is half an inch, which is overall impressive. Creating heavy arcs depends on the material’s thickness. If the material is thick, the performance becomes even more convenient and efficient.
Final Thoughts
Aluminum is one of the most widely used metals in the world. Learning to shape aluminum into any form and manipulate it can give you a lot of creative possibilities. If you need to repair aluminum parts, you wouldn’t need to hire a professional, and you can do the job of welding yourself. Welding aluminum can be a fun weekend pastime or even become a lucrative profession. When you weld metal as sensitive as aluminum, it is crucial to know the proper methods and care required. It is crucial to invest in the best aluminum welding machine that can do the job properly.
