Aluminum Welding

Stable Connections, Lightweight

Challenge of Aluminum Welding

Alongside steel, aluminum is the most widely used construction material. Its biggest advantage is that it is just as strong but only around half as heavy. The use of aluminum is therefore preferred for lightweight constructions.

Interesting Facts About Aluminum

Pure aluminum (Al99.5) is not very strong. However, it is used as the basis for alloys with a strength that matches up to steel.

Welding aluminum is particularly difficult because the material is surrounded by an oxide layer. This only melts at around 3659 degrees Fahrenheit, while aluminum itself melts at around 1202 degrees depending on the alloy. If the oxide layer were to be melted in the conventional manner then the aluminum would run away, and welding would be impossible. It is therefore necessary to destroy or displace the oxide.

What alloys of aluminum are there?

The properties of pure aluminum can be changed using alloys. For example, adding magnesium considerably increases the strength of the material.

The most important components of aluminum alloys and their properties are:

  • Magnesium (Mg)
    0.3–7% higher strength, finer grain size
  • Manganese (Mn)
    0.3–1.2% better corrosion resistance, higher strength
  • Copper (Cu)
    roughly 5% higher strength, lower corrosion resistance, important for hardening capacity
  • Silicon (Si)
    12% for casting, reduces the melting point to 1070,6°F, however with coarse grains


  • Very light but strong
  • Corrosion resistant
  • Temperature resistant
  • Not sensitive to UV radiation


  • Expensive parent material
  • Difficult to weld

Professional Power Sources for Aluminum Welding

TPS 320i
  • MIG/MAG welding system
  • Integrated data documentation
  • Intuitive touch display
Find out more about TPS 320i
TransSteel 2200
  • Multiprocess system: MIG/MAG, TIG, manual metal arc welding
  • Portable and light for mobile use
  • Intuitive operation and easy menu navigation
Find out more about TransSteel 2200
MagicWave 230i
  • Alternating current TIG welding system from the new generation
  • Intuitive menu navigation
  • Can be expanded with optional function package
Find out more about MagicWave 230i

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