Aluminum welding techniques for precise, repeatable TIG results

If aluminum still feels unpredictable—warping, soot, lack of fusion—this field manual compresses proven aluminum welding techniques into clear, repeatable steps. TIG Welding Secrets gives you exact AC balance, frequency, and amperage baselines by thickness; correct filler selection (4043 vs 5356); torch angle and travel speed to control heat input and puddle shape. Eliminate porosity with proper oxide removal, tight fit-up, and targeted preheat.

Created by a CWI and former aerospace fabricator, this guide delivers parameter charts, joint-prep checklists, and troubleshooting flows for 5xxx/6xxx alloys across fillet, lap, corner, and butt joints. Apply consistent procedures to produce clean, strong, cosmetic beads on thin sheet and heavy plate. These aluminum welding techniques reduce rework, speed fit-up, and raise first-pass yield in both shop and field conditions.

• Dial-in settings for 0.040–1/4 in material with AC balance and frequency presets.
• Pulse and foot-control routines to tame heat, limit distortion, and nail starts/stops.
• Defect fixes: soot/black smut, porosity, lack of fusion, and crater cracking.