Tips for TIG Welding Aluminum that deliver clean, repeatable results

If you’re chasing pore-free, ripple-consistent aluminum TIG welds, you need more than generic advice. Everything You NEED to Know About TIG Welding translates hard-won shop data into precise, repeatable settings and motions. It compacts proven tips for TIG welding aluminum into clear, step-by-step guidance—so you spend less time troubleshooting and more time producing strong, clean joints.

Written by certified TIG specialists and validated in fab, motorsport, and marine work, it provides exact starting points, decision paths, and quick calibration checks for any thickness or alloy. Expect fewer burn-throughs, cleaner etch lines, flatter beads, and predictable penetration—without guesswork.

• Dial-in AC: 65–75% EN balance, 90–150 Hz, 100% Ar (Ar/He for heavy plate), #8–12 gas lens, 15–20 cfh.
• Prep and technique: degrease, remove oxides with a stainless brush, 1× tungsten arc length, 10–15° push angle.
• Defect control: crater fill and taper-out, heat management, 4043 vs 5356 filler selection, preheat >6 mm sections.