How to Weld Aluminum with Stick Welders

Getting straight with your welding procedure requires some of the basic to technical points in consideration. Welding aluminum with stick welders is as easy in some ways but complex as well. People choose aluminum because it is non corrosive, lightweight, and pleasing to the eye. In order to do the job soundly we must take care of the fact that the material is soft, highly sensitive and is insulative by a tough oxidized layer. Summing up your query of how to weld aluminum with stick welders is as described as:

Cleaning the Surface

The cleaning of the aluminum surface from the dirt, grit and other contaminants is necessary that might cause a flaw in the process. The queries of why cleaning is important before the stick welding process and how it can be properly done are explained down.

Why Cleaning is Important?

The surface of the raw aluminum might contain debris and dirt that might cause menace in the process—that are:

Fire Sparks

The fire sparks are the byproduct of any metal arc welding (stick welding), not cleaning the aluminum will increase the ratio of them.

Unbalanced Welding

The dirt on the aluminum surface is turned into fire sparks, that in larger extent will block the visibility of welding point, thus irrupting the balance and accuracy of work.

How to Clean the Aluminum Surface?

The cleaning of aluminum surface is not a big deal even for a layman. Just follow these tips and you will be good to go;

  • Take acetone or any other solvent i.e., strong soap.
  • Remove oil, and greases.
  • Take a dry non-linted cloth to clean the surface.
  • Clean water vapors and moisture from the surface.

Remove Surface Oxides

If the aluminum is old and placed in a moisture, then it might catch surface oxide. For efficient cleaning, the surface needs to be cleaned from these oxides.

How to Remove Surface Oxides?

The cleaning of the surface oxide can be done as;

  • Use stainless steel wire brush.
  • Rub effectively on the surface oxides.
  • If the oxides are stubborn, add strong alkaline or acid in the rubbing.
  • Rinse the whole part
  • Fully dry the surface before welding.
  • Assemble the Joints

The joints are the points where two different parts are welded. Assemble and cover them—especially, if you are not welding now. Assembling the joints will help you prep for the welding process.

Gauge the Potential of Stick Welder

The too much flow of gas will likely cause an irregular arc—if you are using argon or helium or any other mixture then make sure to gauge the flow and customize the potential otherwise, it will only cause disruption and unbalanced welding.

Using the Best Electrode

The electrode used in the welding process need to be relevant—suitable to the sort of welding that is being used. The choices are:

For TIG Stick Welding

  • The tungsten electrode is the best choice for TIG welding for aluminum.

For MIG Stick Welding

The finest electrode for MIG stick welding depends on the sort of thickness and base metal you are dealing with. The relevant and most suitable electrodes are:

  • ER4043
  • ER5356

Do the Weld

After cleaning the surface of aluminum, removing the surface oxides, drying the aluminum, and selecting the suitable welding electrode, now is the time for the real task. The neatness in welding is much dependent on the practice rather than the theoretical knowledge—the timing, and angle is much developed by using the stick welder continuously, especially under the supervision of professionals. Contrarily some of the factors are needed to be taken account of while welding;

Maintain the Appropriate Distance

The distance of the burning stick welder from the joints or the surface, plays a keen role in the process. If you are too near to the surface then too much heat might disrupt and make the weld unbalanced. On the other hand, if you are welding from much far, then melting would take long.

Selecting the Equipment

You might know the decorum of the process but the tools play a keen role in the efficiency of welding. Choosing the right welding machine according to your decorum will help you. Based on the features, compatibility, user convenience, power range, and the welding capacity, our researchers have craved out the relevant welders that are:

Not only the welders, but the best safety measuring products used in the welding process are likewise researched out;

The Process is Quick, Keep your Reflexes Active

Melting of the aluminum during the welding process is swift especially when you are using the stick welder. Even if the process is not handled by any layman, still they need to take account of reflexes during the weld. The fire sparks will cover the visual of weld thus, if you are a layman, consult the supervision of professional welders.

Tips to Rekindle for Finest Aluminum Welding

Using the DC TIG Stick Welder

The best shielding gas for DC TIG stick welder is helium that attains hot arc for deep penetration most suitable for thicker aluminum welds.

Using the AC TIG Stick Welder

The common myth that roams in the forums is that using the AC TIG with argon shielding gas, but the pro tip that makes it the slowest, cleanest, and most controllable way to weld aluminum is the argon or helium mix. This mixture of gases is good for thin aluminum.

DC TIG with Argon and Flux

The welding of aluminum by DC TIG with argon and flux welds aluminum but the cleanup is not very good to kindle.

MIG rather than TIG Welding

Choosing MIG welder over TIG would affect your working process, as the MIG is fast but the factor that revises the consideration about the MIG is that you cannot melt the base metal without filter metal.


The welding of aluminum with stick welders is just complex as it seems to be simple. The tiny technicalities might cause disruptions in the process. This guide holds the information to carve out the best results with the help of right process to weld. Know-how of the welding acquires the steps as to clean the aluminum surface before welding, removing the surface oxide from the aluminum, choosing the best stick welder & electrode relevant to the task, maintaining an appropriate distance from the surface, and setting up an optimum flow of shielding gas. Likewise, rekindling some of the tips such as using the right electrode with DC TIG stick welder, and using the MIG (metal inert gas) welding rather than TIG (tungsten inert gas) welding—clearing up the reason is discussed in this guide.

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