Guide to Aluminum Welding Resources and Products

Everything You Need for Aluminum Welding

Whether you're new to aluminum welding or have been doing it for years, you need to efficiently make strong, good-looking welds. Aluminum welding isn't difficult, it's just different — with the right equipment and consumables, you can confidently weld aluminum all day.

Ask an aluminum specialist about your welding challenges.

 

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Aluminum Welding Knowledge Center

Guide to Industrial Aluminum Welding

Get tips for successfully welding aluminum, including prep, storage, process selection and handling common challenges.
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Reducing Rework in Manufacturing: 5 Tips to Improve MIG Welding Sheet Metal

Learn how to reduce heat input and improve results when welding sheet metal, to reduce rework in manufacturing applications.
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TIG Welding Aluminum for Beginners: Steps 3 & 4

Andy Weyenberg, Miller motorsports manager, presented four steps for beginning aluminum TIG welders at SEMA 2009. The final two steps detail forming the puddle and adding filler metal.
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How to Improve the Look and Quality of Aluminum TIG Welds

Learn more about using proper polarity, adjusting balance control and setting AC amperage independently when welding aluminum.
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Learn How Aluminum and Lightweight Materials are Changing Auto Body Repair

Changing fuel economy standards and materials used in vehicle design are placing new demands on collision repair shops.
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How to TIG Weld Aluminum, Plus MIG Weld, With One Multiprocess Welder

The Dynasty® 280 DX Multiprocess welder provides portability and ultimate versatility to weld many different materials.
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BarbieTheWelder Creates Metal Sculpture Art With Miller® Welders

BarbieTheWelder shares her passion for welding and metal sculpture with thousands of followers — and she relies on Miller.
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MIG Aluminum DIY: Selecting the Right Welder, Spool Gun and Filler Wire for Success at Home

One of the hottest trends in welding at home or on the farm is adding MIG aluminum capabilities to a Millermatic® all-in-one MIG welder by complementing it with a Spoolmate™ 100 or Spoolmatic® spool gun.
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TIG Welding Anodized Aluminum with Advanced AC TIG Waveform Controls Speeds Production for Birdsall Marine Design

Miller Dynasty® 350's superior arc shaping capabilities cut welding time by 50 percent, improve weld quality and efficiency for Florida fabricator. Advanced AC TIG controls help cut through anodized aluminum much easier than older TIG technology.
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Advances in Aluminum Robotic Welding

Aluminum presents several challenges during the welding process, such as burn-through, warping or lack of fusion. Learn about robotic welding systems.
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Learn 5 Best Practices, Including Pulsed MIG, for Welding Different Materials

Learn more about welding technologies and processes, including pulsed MIG, that offer benefits for welding different materials.
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An Introduction to Pulsed GMAW

Pulsed gas metal arc welding (GMAW) can offer companies quality and productivity advantages, including for welding operators of varying skill levels. In some cases, companies may be hesitant to adopt the process, but it can offer distinct advantages.
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From Basic to Advanced: Wire Feeders Impact Quality and Productivity

Having the right wire feeder for the job can play an important role in reducing unnecessary downtime for addressing issues associated with poor wire feeding. Options include basic, intermediate and advanced wire feeders.
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Fan Manufacturer Standardizes on Pulsed MIG Welding for Aluminum

Pulsed MIG improves productivity, reduces reject rates and provides Greenheck with welding versatility not possible with older technology.
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Aerospace Fabricator Reduces Power Draw, Improves Weld Performance with New Fleet of AC/DC TIG Welding Inverters

Ace Clearwater Enterprises, specialists in complex formed and welded assemblies for the aerospace and power generation industries, improved energy efficiency and weld performance by replacing a fleet of 23 transformer-based TIG welders with brand new AC/DC TIG inverters.
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Racing Wheel Fabricator Switches to Welding Inverters; Improves Production Speeds and Reduces Power Draw

Advanced TIG, Pulsed MIG processes improve speed and performance on highly engineered aluminum (6061 and 356) components for off-road racing.
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New Advanced Aluminum Welding System Spurs Production on Bollinger Shipyard's U.S. Coast Guard Fast Response Cutter (FRC) Contract

Before any of the U.S. Coast Guard’s Fast Response Cutter (FRC) patrol boats hit open water, they begin their journey up 60 miles of waterway through Bayou Lafourche in Lockport, La. That’s where Bollinger Shipyards builds the Coast Guard’s newest vessel for conducting search and rescue, drug and illegal immigrant interdiction, homeland security and mainland defense.
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How to Reinstall a Trimmed Liner in Your MDX™ MIG Gun

Learn how to reinstall a trimmed liner in your MDX-100 or MDX-250 MIG gun.

How to Replace Your MDX™ MIG Gun’s Handle, Switch and Neck

Learn how to replace the handle, switch or neck on your MDX-100 or MDX-250 MIG gun.

How to Change Consumables on Your MDX™ MIG Gun

Learn how to change the nozzle, contact tip, gas diffuser or liner on your MDX-100 or MDX-250 MIG gun.

Syncrowave® TIG Welders: General Setup Steps

See every step needed to unbox your new Syncrowave TIG welding power source, finalize its assembly and get it ready to power on.

Syncrowave® TIG Welders: Set Processes and Parameters

See every step needed to set processes and parameters on your new Syncrowave TIG welding power source — so you can get welding!

Welding Aluminum With the Dynasty 280 DX Multiprocess Welder

When welding aluminum, follow these tips to set up your Dynasty 280 DX Multiprocess using an ArcReach SuitCase 12 feeder.

Syncrowave® 300 and 400 TIG Welding Power Sources

Outdated equipment holds your operation back. Get current with Miller® Syncrowave® 300 and 400 TIG welding power sources!

Miller Dynasty TIG Welding Power Sources: No Compromises

Miller Dynasty TIG welding power sources have versatile operating parameters for strong, precise, beautiful welds.

Dedicated Aluminum Welding Systems Minimize Quality Issues

A dedicated aluminum welder, like a Millermatic 350P Aluminum or AlumaFeed can reduce quality risks, and reduce cleanup.

Selecting the Right Gun for Aluminum Welding

Guns designed specifically for aluminum welding are capable of feeding the soft wire, while also minimizing wire-feeding problems such as bird-nesting.

Adjusting AC Frequency to TIG Weld an Aluminum Cylinder Sleeve

Chris talks about welding dissimilar thicknesses of aluminum with the help of the Dynasty 350 and the adjustable AC frequency controls.

Welding in Tight Spaces on ’32 Euro Coupe using Miller Weld-Mask and Diversion 180

Hollywood Hot Rods fabricator Sean welds in tight spaces on a ’32 Euro Coupe. For the project, he relied on the Diversion 180 TIG welder.

Cotati Speed Shop - Miller Use Diversion™ 180 to Create Aluminum Air Pan for '48 F1 Ford Pickup

Miller product manager John Swartz shares TIG welding techniques as he works on an aluminum air pan from Santa Rosa, Calif.-based Cotati Speed Shop.

Chris Razor Discusses Advanced AC TIG Welding Controls on Aluminum

Chris of Hi-Tech Welding shows advanced AC controls for welding aluminum, including independent amperage control, balance and frequency.

PAR Racing Engines Repairs Engine Block with Dynasty 350 TIG Welder

Miller's Andy Weyenberg and Scott Duggins, PAR Racing Engines, repair an engine block and recommend Dynasty 350 settings for aluminum welding.

Benefits of frequency adjustment on aluminum using the Miller Dynasty 200 DX TIG welder

Miller Marketing Manager John and Pure Vision fabricator Aaron Cranford discuss modifications to the radiator in the Pure Vision TT Camaro.

Dynasty 280 and Weldcraft Torch Provide Versatility for Aluminum Boat Repairs

Out Back Aluminum Welding relies on the Dynasty 280 DX TIG/Stick welder to gain flexibility and portability for TIG welding on boats — in the shop or at the marina.

Miller Multimatic 215 MIG (GMAW) Welding Aluminum Setup

Watch for step-by-step instructions on how to set up the Miller® Multimatic™ 215 for MIG (GMAW) welding aluminum.

Postflow when TIG Welding

Learn about the value of postflow and what to look for if postflow is not set properly. Without proper settings the tungsten and even the weld could become contaminated.

Proper Cleaning Techniques Tied with Balance Control

Miller welding engineer explains how balance control can be adjusted based on the cleaning prior to welding. Having a clean surface allows you to increase your balance control.

Applications for AC Frequency Adjustments

Learn when to use a low frequency setting versus when to use a high frequency setting.

Pulsing with TIG

Miller Welding Engineer Zack Erndt explains the benefits of using pulse when TIG welding and talks about applications where low and high pulses per second can be used.

Miller Spoolmate 100 MIG Gun for Welding Aluminum

The Spoolmate 100 is the economical and versatile solution for welding aluminum with your Millermatic, handling 4043 alloy and 0.30 to 0.35 aluminum wire.

How to MIG Weld Aluminum with the Multimatic 220 AC/DC

Setting up you Multimatic 220 AC/DC to MIG weld aluminum is easy. Follow these steps to get started.

H&W Pacific Emergency Vehicle Group Updates Shop with Versatile Welding Equipment from Miller

H&W decided an update in welding equipment was needed to keep up with growing demand for aluminum and stainless materials.

H&W Operators Find Invision Welding System User Friendly with Better Arc Control

H&W Pacific Emergency Vehicle Group uses Invision 352 MPa Plus to increase productivity thanks to more control and longer leads.

Miller Millermatic MIG Welders - Aluminum Welding

Aluminum welding. How to MIG weld on aluminum with a Millermatic and a Spoolgun. set up and weld techniques are covered.

Welding Aluminum with Miller's Millermatic MIG Welders

Fort Defiance Industries Relies on Miller Dynasty Machines

The Miller® Dynasty® machines used by Fort Defiance Industries provide capabilities for a dynamic manufacturing environment.

Miller TIG Welders Deliver Best Arc for Manufacturer

Fort Defiance Industries manufactures critical medical devices for the U.S. military with the help of Miller Dynasty® machines.

K-zell Metals and the AlumaFeed Synergic Aluminum Welding System

K-zell Metals relies on Miller's AlumaFeed Synergic System for welding aluminum components. Benefits are excellent arc starts and aesthetics.

TIG Welding Aluminum Tanks with the Miller Syncrowave 210

Andy Weyenberg and Joe Constance of Joes Racing Products use the Syncrowave 210 TIG welder to fabricate custom aluminum tanks.

Welding with Aluminum: Find the Best Process for Your Specific Application

Welding with Aluminum: Find the best process for your specific application

Setting Up Your Multimatic® 235 to MIG Weld Aluminum

Learn how to set up your new Multimatic 235 welding power source to MIG weld aluminum with a spool gun.

Millermatic 350P Aluminum Set Up and Operation

An in-depth look at the settings and capabilities of the Millermatic 350P, an all-in-one MIG welding system designed specifically for aluminum.

Multimatic® 235: Access Service Menu and Calibrate Spool Gun

Learn to access the service menu on your Multimatic® 235 welding power source and use it to calibrate the motor on your spool gun.

Smoky Mountain Jet Boat Built with Pulsed MIG Technology

Jet Boats is building aluminum in the mountain woods, using Miller's latest Pulsed MIG technology to ride the wave of boat orders.

Miller's Aluminum Welding System Helps Metal Shark Aluminum Boats

Metal Shark increased efficiency, doubled production and cut welding time in half by using Miller's aluminum welding system.

Should You Use Pulsed TIG Welding for Aluminum?

Pulsed TIG welding can provide better results with aluminum. Learn about the capabilities of the Multimatic 220® AC/DC welder.

Fabricator Reduces Power Draw by 25-30% with Miller Welding Inverters

OMF Performance Products reduced power draw substantially by switching from an old transformer-based welder to two inverter-based welders.

Aluminum TIG Welding: AC Balance Explained

Proper AC Balance settings are critical to weld performance, quality, and tungsten life when TIG Welding.

At Pure Vision, the Cars and People Are Anything but Ordinary

Pure Vision has become a world-renowned street machine fabrication shop, known for a very signature concept and build style.

Rick's Restoration Relies on Miller Pro-Set Feature

Tyler Dale and the rest of the team at Rick’s Restoration utilizes the Pro-Set™ feature on their Miller® TIG welders in the shop.

Overview of Pure Vision's Twin Turbo Camaro Build

Located in Simi Valley, Calif., Pure Vision has become a world-renowned street machine fabrication shop, known for a very signature concept and build style that can be described as simple, straightforward and well-detailed. In this video, shop owner Steve Strope shares a quick overview of the Twin Turbo Camaro build that the shop is currently working on.

FABTECH 2013: Tony Anderson on the Benefits of New Aluminum Filler Metal 4943

Tony Anderson, director of aluminum technology, discusses the first new aluminum filler metal to be developed, in nearly five decades.

Preventing Porosity in Aluminum Welding

Tony Anderson, director of aluminum technology, discusses the causes of porosity when welding aluminum.

TIG Welding Aluminum: AC Frequency Control

Learn how to adjust AC frequency to gain greater arc puddle control when TIG welding aluminum on Miller Maxstar or Dynasty TIG welders .

Miller's Aluminum Welding System helps Metal Shark Aluminum Boats

Metal Shark increased efficiency, doubled production, and cut welding time in half by using Millermatic 350P pulsed MIG welders.

Bollinger Shipyards and Advanced Pulsed MIG Welding on Aluminum

Bollinger Shipyards improves productivity and simplifies aluminum welding on patrol boats with Miller's advanced AlumaFeed™ Synergic Aluminum.

Save Space on Work Trucks With Diesel All-In-One Solutions

Operators of class 3 to 5 service trucks can consolidate their power equipment with a fuel-efficient, all-in-one solution.

Chris Razor Discusses Advanced AC Controls, Trianglulated Waveform for TIG Welding

Chris Razor of Hi-Tech Welding discusses independent amperage, balance and frequency settings on his Dynasty 350.

Pure Aluminum Hull Built with Miller Welders: Smoky Mountain Jet Boat Goes for a Ride

Smoky Mountain Jet Boats are assembled using Pulse MIG from Miller welding equipment.

Sportsfield Specialties and Pulsed MIG Welding with the New Millermatic 350P Aluminum

Sportsfield Specialties found solutions to their aluminum welding challenges when it implemented a Pulsed MIG welding process.

Chris Razor of Hi-Tech Welding Discusses TIG Inverters

Listen to the advantages of TIG inverters: increased productivity, greater quality, greater energy efficiency, advanced controls.

Marcella Manifolds & TIG Welding Aluminum Manifolds

Owner of Marcella Manifolds discusses the evolution of GTAW welding, including the advanced AC TIG controls.

Miller's AlumaFeed™ System Excels in Aluminum Shipbuilding

Bollinger Shipyards is able to simplify operation, improve productivity, improve quality, reduce distortion, and reduce bird nesting.

MillerWelds Exclusive: Advantages of Pulsed MIG on Aluminum at Greenheck Fan

Greenheck Fan discusses the benefits of Pulsed MIG aluminum welding in aluminum applications in its Wisconsin manufacturing facility.

Accessories and Components to Help Solve Your Welding Problems

At Richard Childress Racing, fabricators address many welding challenges — just like you do in your shop or home garage.

Smoky Mounatin Jet Boat Relies on Partnership with Miller and Local Distributor for Solutions

Smoky Mountain Jet Boats builds 100% aluminum watercraft. The company turns to Miller for the latest Pulse MIG welding technology to get the job done.

Tips for Choosing the Right Welder for Your Application

It’s important to consider the input power available, material to be welded, and the prime window in which a specific machine operates best.