Aluminum welding techniques for precise, clean TIG results

Aluminum is unforgiving—its oxide skin melts around 3,700°F while the base metal gives way near 1,221°F. Without disciplined control you get soot, porosity, and warping. Everything You NEED to Know About TIG Welding compresses proven aluminum welding techniques into clear, repeatable steps so you can lay down bright, tight beads with confidence.

Inside you’ll find exact setups for common thicknesses (1/16"–1/4"), with AC balance and frequency baselines by machine type, amperage and cup sizing, and when to choose ER4043 vs ER5356. You’ll get shop-tested procedures for joint prep (degrease, mechanical clean, fit-up), torch angle and arc length, foot pedal control, crater fill, and heat management using pulse, chill blocks, and backing. Built from thousands of hours on 6061 and 5052 in fabrication and repair, it pairs WPS-style checklists with troubleshooting matrices to quickly eliminate black soot, grainy puddles, and blow‑through.

• Repeatable parameters that produce pore-free, satin-clean welds.
• Faster setup with fewer test passes and less rework.
• Practical fixes for contamination, distortion, and inconsistent starts.