How to MIG Weld Aluminum: The Complete Guide

Aluminum MIG is awesome...when it's going well. Watch this to make it go well more often.

Introduction 00:00
Machines 0:25
Setup 1:45
Filler Metals 2:20
Settings 4:23
Technique 7:07
Controlling Heat 10:22

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***Videos Mentioned***

Gas Metal Arc Welding (GMAW), also known as MIG welding, can be used very effectively on aluminum with good practice. In this video, we complete welds both with and without a spool gun.

[donprice]

I got a job building horse trailers and not just tossed into welding on day 1, but MIG welding aluminum. Talk about getting thrown into the deep end. It felt like a vacation when I went over to steel utility trailers in the next job.

[bwilson]

Man this is the best video on welding I have ever seen. I learned more in 13 minutes that hours on hours of other videos. So many people don’t explain the reason. I need to no reasons not because this is what I was taught. Appreciate this video my friend.

[davidcox]

Tim, you're and absolute You have helped me so much from knowing nothing about welding to setting up some work on the side and making some extra cash!! Invaluable resource you are!!! Thanks.

[ZILAwelds]

Wow, what an excellent video !!! I could have watched another 20 min….

[Hey_Its_That_Guy]

Another great one, Tim. I've never welded aluminum, but am eager to try. Your tips will help for sure. Your practical presentation style takes the mystery out it. Appreciate your time and effort!

[trace]

Thanks Tim. You saved me a lot argon & wire. I recently purchased a Miller 235 w/Spoolmate 200. The auto set for 1/8" aluminum is 21.9 volts with 575 wire speed. Not matter how fast I went it was more like a plasma cutter than welder. Your settings worked great.

[dennisonseeto]

Thank you! Your basic settings helped get me dialed in with my welder very quickly!

[HepauDK]

The handles we used at Maersk Container Industry (Denmark) back in the late 90's had a set of assisting rollers directly in them, as well as a dial to control the current/feed rate.
Having a welder with the slope down feature helps immensely. If the pool gets too big or hot, you just release the trigger for a second an continue.
One thing to note for the beginner aluminium welder, is that you need to move the handle much faster than when welding steel. Oh, and it is absolutely essential that the material is as clean as possible. You don't want to turn your welder into a plasma cutter...

[MartinVogel-evnq]

I just started welding about a year ago with steel and have been wanting to do aluminum, kept wrecking tips! This is a great video thank you!!!

[miguelheras]

Best lesson I have seeing, I putted in practice your comments have improve my work Thanks.

[thatguy]

I woke up thinking about learning to weld… and this comes up in my feed.

[theezeelife]

Thanks for this video. Watched another video on this and they were talking about using a $12, 000 machine specially made for aluminum welding. It had special rollers, tensioner, had water cooling, etc. I can't afford all that. Thank you for showing how to do this with basic machines.

[jeremiahbullfrog]

HTP RULES! I have the HTP Pro Pulse 220 MTS, it welds VERY WELL.

[TannerMarkley]

thank you so much, just decided I'm going to weld my own projects i needed as i couldnt find a consistent welder and I went out and bought all the stuff you mention in this video. I've watched this video 5 times now

[aleksanderlikar]

You gave a clear, concise, fluid, and well-explained explanation.
Thanks man.

[SM-hynp]

Very good video. Gave all the basic details needed, very well explained on each point and showed good examples. Thank you for sharing your time to create this video for the public.

[donaldwilliams]

WOW, Its already been said, but I will say it again. By far the best educational video I have ever seen. Great Job Tim.

[DStein-jnls]

Thank you, Tim. I have that exact Harbor Freight welder and have wanted to weld aluminum, but was not sure where to begin. I think your video has given me a great start!

[cangooner]

Super timely video as I'm going to play with my spool gun for the first time tomorrow. Thanks! 👍

[jonathanwiggill]

Thanks Tim! Busy dialling in my Yes Welder MIG250Pro on some 0.08" wall-thickness aluminum tubing now and stopped to Google why I am having difficulty and found your video... Your advice about allowing more stick out on aluminum is really useful!! I learned a valuable lesson here that has helped me avoid the wire melting onto my contact tip! Also starting up high and coming in to your recommended stick out distance is also super useful advice for a novice like me! Thank You Again!