Tips for TIG welding aluminum: proven techniques for cleaner, stronger beads

Aluminum magnifies mistakes—oxide, heat soak, and inconsistent puddles can ruin a part fast. TIG Welding Secrets condenses the most reliable tips for TIG welding aluminum into precise, repeatable workflows so you can control heat, eliminate porosity, and lay inspection-ready beads on thin sheet or heavy sections. Developed by veteran instructors and production TIG specialists, it details the exact setups and hand skills that hold up on the shop floor.

Inside you’ll learn how to set AC balance and frequency for effective oxide cleaning without over-etching, prep tungsten for modern inverter AC, choose the right filler (4043 vs 5356), and dial gas coverage that truly shields. Master fit-up, preheat, torch angle, and pedal modulation to keep the puddle tight, minimize distortion, and prevent crater cracks. Expect fewer reworks, faster travel, and brighter, uniform welds that pass visual and bend tests.

• Step-by-step parameters and checklists for common joints and thicknesses
• Field-tested fixes for soot, black pepper, lack of fusion, and porosity
• Compact references you can trust under deadline and audit