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How to Weld Aluminium with MIG

How to Weld Aluminium with MIG

MIG welding is a great choice for welding aluminium components because it can be used with or without shielding gas and is less likely to cause warping or cracking than other types of welding. With the right tools, any welder can learn how to weld aluminium with MIG. Let’s look at what you need to know to get started.

Basics of MIG Welding

MIG (Metal Inert Gas) welding is a type of arc welding that uses a consumable wire electrode and an inert gas, such as argon or carbon dioxide, to protect the weld from contamination. The basic process involves feeding the wire electrode into the weld pool and striking an arc between it and the base metal. As the wire melts, it forms a bond between the two pieces of metal being joined together. Because MIG welding does not require many fluxes as stick welding does, there is less risk of contamination affecting your welds.

Welding Aluminum with MIG

Aluminum is one of the most difficult metals to weld because it has a low melting point and is highly reactive when exposed to heat. That’s why it’s important to be sure you have all the right tools before attempting this kind of project. You will need a special aluminum-capable MIG gun, which has larger diameter contact tips than those used for steel so that more heat can be transferred into your workpiece without damaging it. You will also need special aluminum-specific filler rods for making your welds and proper safety gear, such as gloves and goggles. Once you have all the equipment you need, you can begin by preparing your workpieces for welding by cleaning them thoroughly and ensuring they are properly clamped together before starting your welds.

Optimizing Your Welds

Several factors must be considered when using MIG welding on aluminum components if you want to optimize your results. One thing to remember is that aluminium requires lower amperages than steel to achieve proper penetration. Even though you might be using higher amperage settings when welding steel components, more than these settings may be needed when working with aluminium parts. So always start low and adjust accordingly until you find what works best for your application. Additionally, because aluminum has such a low melting point compared to other metals, it tends to form “cold laps” -whereby small amounts of material do not fully melt during the process- which can lead to weak spots in your finished welds if not properly addressed during setup or execution of your welds. To prevent this from happening, make sure that your travel speed is slow enough so that each bead gets filled before moving onto another area; otherwise, you could end up with unsightly porosity in some areas, while others may appear overly thin due to incomplete fusion between layers. Additionally, ensure that everything is properly clamped down since aluminum tends to move around more than other metals when exposed to high temperatures due to its relatively low thermal conductivity – meaning more repositioning will likely be required during your projects compared with other types of metals like steel or magnesium.


MIG (Metal Inert Gas) welding is an ideal choice for joining aluminum parts together because its portability makes it easy to use in many different environments while also providing superior penetration compared with other types of arc welding processes, such as stick welding or TIG (Tungsten Inert Gas). However, due to aluminium’s lower melting point, certain precautions must be taken when operating an aluminum-capable MIG gun, such as using lower amperage settings than those used for steel and slower travel speeds so that each bead gets filled before moving onto another area; otherwise, cold laps may form which can lead too weak spots in your finished welds if not appropriately addressed during setup or execution. With these things in mind, anyone who would like to learn how to weld aluminium with MIG should easily understand how best to optimize their results after reading this article!

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