For aluminium, clean the metal thoroughly, remove the oxide layer with a dedicated stainless steel wire brush, and weld using AC TIG with pure Argon shielding gas and the correct filler rod (usually ER4043 or ER5356). For thin sheet metal, TIG’s precise control of heat input is the key advantage — use a small-diameter tungsten, low amperage and a short arc length to minimise distortion.
How do you TIG weld aluminium plate?
Clean the aluminium thoroughly, remove the oxide layer with a dedicated stainless steel wire brush, and use AC TIG with pure Argon shielding gas. Select the correct filler rod — usually ER4043 or ER5356, depending on the alloy. Good preparation and correct machine settings are essential for producing strong, clean aluminium welds.
A few points underpin this:
- AC current is used for aluminium because it helps remove the oxide layer during welding. See our AC vs DC TIG welding guide.
- Filler choice comes down to the alloy and application — ER4043 for general fabrication and crack resistance, ER5356 where higher strength or improved corrosion resistance is needed. More detail is in our TIG filler rod guide.
- Tungsten — Zirconiated (white) tungsten is often used for AC aluminium welding, and a balled tip is normal in this mode. See our tungsten electrode guide.
How do you TIG weld thin sheet metal?
TIG welding is ideal for thin sheet metal because it allows precise control of heat input. Use a small-diameter tungsten, low amperage and a short arc length to minimise distortion. Tack weld first and move quickly to prevent excessive heat build-up. For stainless steel, use the correct filler rod and shielding gas to maintain corrosion resistance and achieve a clean finish.
Pulse TIG welding further improves control on thin materials by reducing heat input while maintaining penetration, which helps minimise distortion.
Consumables for aluminium and sheet work
The right combination of AC machine, tungsten, filler rod and gas makes aluminium and thin-sheet TIG welding far more forgiving. The Weldability SIF team can recommend the correct consumables for your alloy and thickness — contact us for advice.