Aluminum TIG Welding Guide for clean, consistent results

This aluminum TIG welding guide is the focused, no-nonsense section of “Everything You NEED to Know About TIG Welding” built to eliminate guesswork on aluminum. Authored by an AWS-certified educator with shop and field experience, it translates real parameters and procedures into repeatable outcomes—no fluff, just what works. If you’re battling black soot, collapsing edges, or inconsistent bead profile, you’ll learn exactly how to prep 5052/6061, choose the right tungsten and filler, and dial in AC balance, frequency, and amperage for every common thickness.

Inside, you’ll get step-by-step setups, thickness-specific tables, and troubleshooting trees for porosity, oxide contamination, crater cracking, and distortion control. We detail gas flow and cup selection, stick-out, pre/post flow, pulse recipes, torch cooling, and pedal technique—plus joint-specific techniques for butt, lap, fillet, and corner joints, in and out of position. Written in clear, technical language and validated in production environments, this guide helps you produce tight, shiny, structurally sound welds that meet inspection standards without endless trial-and-error.

• Parameter charts that work: AC frequency/balance, amperage by thickness, filler choice, gas flow, cup size vs. stick-out.
• Repeatable technique: torch angle, arc length, travel speed, dab timing, and how to read and control the puddle.
• Quality assurance: quick etch checks, bend tests, and acceptance criteria aligned with AWS D1.2 best practices.