TIG Welding Thick to Thin Aluminum

Two lesson examples on TIG welding Thick to Thin Aluminum in one episode! Justin shows us a realistic welding job on a coolant tank as well as some practice examples on aluminum coupons.

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[AkPacerPilot]

Makes me feel so much better, that I’m not the only one dipping the tungsten occasionally…. Good stuff, thanks!

[plokijij]

I have been trying to tig weld for months! I have bought a ton of stuff, cups, lenses, different tungsten and still my welds were terrible! Until yesterday after exhausting every possible reason for my results I looked at the gas bottle which said Argon, but when I looked again it is speed shield argon for mig!! Which is not straight argon!!! I can’t believe after watching months of watching videos and not understanding what was happening it if a basic thing that was the cause. As pissed as I was I quickly became relieved that now my welds are starting to look like they should!

[mattlarson]

I love your honesty. I hate it when people make it look like they did something perfect on the first try with their eyes closed.

[Chris-vxkp]

This reminds me of the time I had to weld some thick stainless steel fittings to a 16 guage stainless panels to be assembled into a box. I did it this way so I could using backings to prevent sugaring. They warped the crap out of the panels they were welded to, but once I assembled the panels with the fittings, you wouldn't even know there was a 1/2" "W" on the sides. I water tested each one, and sent it out a total of 4 that Friday. That Friday afternoon hit 107 in the middle of summer, and I was at work till 8pm. That was the day I started looking for an office job, and here I am posting from the office missing welding.

[mysterious_nobody_]

Having watched all your TFS videos, I can definitely tell this is far from your best work. But THANK YOU for showing how important practice is and how many tries it took to get a decent result even for an expert such as yourself. And THANK YOU for keeping the tungsten dips and shaky hands in the video. People tend to show off their one in a thousand best work on photos and videos, and it's easy to look at that and get discouraged with your own work/process. But we shouldn't forget that behind those perfect results were a thousand mediocre practice runs and hundreds of hours of practice. It just takes a lot of practice to develop a steady hand and consistent beads.

Edit: Tips for welding thin parts:
- Use a higher frequency like 180Hz-240Hz for a more stable arc and lower penetration
- Sharpen tungsten to a more acute included angle, like 20°-25° to widen the arc and reduce penetration, and grind a small flat about 0.5mm in diameter to knock the pinpoint tip off
- Preheat the sheet metal with a blowtorch to reduce warping
- Consider automatic pulsing or pulsing with the foot pedal to increase current when you add filler

[donnieji]

You are so kind to help us for free. Give value and get customers. Good method. You will get me and the wife as soon as we finish school. That way we can come to you and your instructors with bit more practice at the basics

[dustinharley]

Justin, good stuff man. I appreciate you keeping it real and being honest about how perishable this skill is. You can never practice too much. Great job explaining the technique for thick to thin parts, I definitely learned something. Thank you!

[donaldmarty]

Thanks for your honesty! Always enjoy your vids and as a weekend DIYer have learned a lot from them learning to TIG aluminum in the last three years.

[tomstocker]

I have learned more from you/your videos than anyone else. You’re a gifted teacher! I feel like I should be paying for the knowledge I’m gaining. Thanks so much!

[scottresch]

Justin you are always as real as it gets man. Thanks for the video.

[mocko]

I have never welded in my life and don't plan to, I just enjoy watching welding.

[ethan....]

Hey Justin, I appreciate the authenticity and honesty in this video. Don't worry about justifying yourself to the commenters, it's not needed brother.

[joemurray]

Your honesty gives me confidence. Thanks.

[BB]

I did learn from this - that no one is perfect, and I mean that with the greatest respect Justin. Doing the welding on that tank, I'd have done it the same way. I've always got annoyed at having a few stop starts whilst welding round tube, but sometimes it's the only way to do it.

[mmwracing]

You’re the Bob Ross of welding man👌🏼 learned so much from this channel

[petersmart]

My first welds with tig were all on soda cans! A friend(35 years as x-ray welder) told me to start by welding soda cans together, because if I can figure out how to weld the cans without blowing them apart, thats a good place to be! Thx for the video!

[anicekevorking]

Welding during the Superbowl, what a pimp. Respect

[JonesMetalCraft]

Great video Justin. I really appreciate your realism and honesty. Thanks!

[LostCanuck]

Seeing you dip your tungsten is so encouraging. When I dip mine, I don't beat myself up about it. Unlike when I watch other video creators videos

[industrialmarinehydraulics]

Really love your videos and learned a lot from them, also love how you didn’t edit everything out of this video to show what really happens in the real world and still rocking right thru it! Keep up the good work and look forward to more of your videos