Welding aluminum can be tricky. It’s not like steel where you can just crank up the heat and go. Aluminum is softer and melts faster, so having the right TIG welder is key. You need a machine that gives you precise control and AC capabilities to clean the aluminum oxide layer. I’ve been welding for over 15 years and have learned what works and what doesn’t when it comes to aluminum. So, I’ve put together a list of some of the best TIG welders for aluminum to help you make the right choice.
Product Overview / Quick Summary:
- Forney Easy Weld 200MP: A versatile machine for beginners covering multiple welding processes.
- Lincoln Electric POWER TIG 210 EXT: A user-friendly, feature-rich TIG welder suitable for both beginners and professionals.
- AHP AlphaTIG 203Xi: Powerful and reliable, offering excellent performance at a competitive price.
- Eastwood TIG 200 AC/DC: A popular choice for hobbyists and DIY enthusiasts, known for its affordability and decent performance.
- Miller Electric Diversion 180: Simple and easy to use, perfect for the home hobbyist looking for a basic AC/DC TIG welder.
Top 5 Best Aluminum TIG Welders
Forney Easy Weld 200MP
The Forney Easy Weld 200MP is a multi-process welder that’s great if you’re just starting out. It can do stick, MIG, and TIG welding, so you can learn a variety of techniques. This machine is lightweight and portable, making it easy to move around your shop or take to job sites.
Pros:
- ✅ Multi-process capability (MIG, Stick, TIG)
- ✅ Lightweight and portable
- ✅ Easy to use for beginners
Cons:
- ❌ TIG torch and regulator not included
- ❌ Lower amperage range compared to dedicated TIG welders
- ❌ Limited advanced features
Verdict: A good option for beginners who want a versatile machine for learning different welding processes, but not ideal for advanced TIG welding of aluminum.
Lincoln Electric POWER TIG 210 EXT
The Lincoln POWER TIG 210 EXT is a step up in terms of features and performance. It’s designed to be user-friendly, even if you’re new to TIG welding, but it also has enough advanced settings to keep experienced welders happy. The AC balance control is crucial for cleaning the aluminum oxide layer, giving you cleaner welds.
Pros:
- ✅ User-friendly interface with color screen
- ✅ Advanced AC TIG controls (frequency, balance)
- ✅ Portable design
Cons:
- ❌ Higher price point compared to some competitors
- ❌ Foot pedal sold separately
- ❌ Some users may find the initial setup slightly complex
Verdict: A great all-around TIG welder that’s suitable for both beginners and experienced welders who need precise control for aluminum welding.
AHP AlphaTIG 203Xi
The AHP AlphaTIG 203Xi is known for its reliability and performance, especially when it comes to welding aluminum. It’s got a strong duty cycle, so you can weld for longer periods without overheating. The digital display and controls make it easy to dial in the exact settings you need.
Pros:
- ✅ Powerful and reliable performance
- ✅ Digital display for precise control
- ✅ Good duty cycle
Cons:
- ❌ Slightly steeper learning curve for beginners
- ❌ Customer service can be hit or miss
- ❌ Some users have reported issues with the foot pedal
Verdict: A solid choice for those who need a powerful and reliable TIG welder for aluminum and are willing to spend a bit more time learning the controls.
Eastwood TIG 200 AC/DC
The Eastwood TIG 200 AC/DC is a popular option for hobbyists and DIYers. It’s affordable and offers decent performance for the price. It has both AC and DC capabilities, so you can weld aluminum as well as steel and stainless steel. I used one of these in my garage for years before upgrading, and it served me well for small projects.
Pros:
- ✅ Affordable price point
- ✅ AC and DC welding capabilities
- ✅ Easy to set up and use
Cons:
- ❌ Lower duty cycle compared to more expensive models
- ❌ Limited advanced features
- ❌ Some users have reported inconsistent arc starts
Verdict: A good entry-level TIG welder for hobbyists and DIYers who want to weld aluminum without breaking the bank.
Miller Electric Diversion 180
The Miller Diversion 180 is all about simplicity. It’s designed to be easy to use, even if you’ve never TIG welded before. There aren’t a ton of bells and whistles, but it does what it’s supposed to do: weld aluminum cleanly and efficiently. If you don’t want to mess with a bunch of settings, this is a good choice.
Pros:
- ✅ Very easy to use
- ✅ Simple interface with minimal settings
- ✅ Reliable performance
Cons:
- ❌ Limited advanced features
- ❌ Lower amperage range
- ❌ Higher price for what you get compared to other brands
Verdict: Best for the home hobbyist who values simplicity and ease of use over advanced features and doesn’t need a high amperage output.
Buying Guide
Choosing the right aluminum TIG welder can feel overwhelming, but here’s what to consider:
- AC/DC Capability: This is essential. You absolutely need an AC TIG welder to weld aluminum. AC current helps clean the aluminum oxide layer for a strong weld.
- Amperage Range: Make sure the welder has a high enough amperage range for the thickness of aluminum you plan to weld. Thicker materials require more amperage. A range of 150-200 amps is a good starting point.
- Duty Cycle: This tells you how long you can weld at a certain amperage before the machine needs to cool down. A higher duty cycle is better, especially if you’re doing a lot of welding.
- Advanced Features: Look for features like pulse welding, AC balance control, and frequency adjustment. These give you more control over the welding process and can improve the quality of your welds.
- Ease of Use: If you’re a beginner, choose a welder with a simple interface and easy-to-understand controls. Some machines have preset settings for different materials, which can be helpful.
- Portability: Consider the size and weight of the welder if you need to move it around frequently. Some welders are designed to be more portable than others.
- Price: Aluminum TIG welders can range in price from a few hundred dollars to several thousand. Set a budget and stick to it. Remember that you often get what you pay for, but there are also some great value options available.
FAQs
Q: Can I weld aluminum with a regular TIG welder?
A: No, you need an AC/DC TIG welder to weld aluminum. The AC function is necessary to clean the aluminum oxide layer.
Q: What amperage should I use for welding aluminum?
A: It depends on the thickness of the aluminum. A general rule of thumb is 1 amp per .001 inch of material thickness. So, for 1/8 inch (0.125 inch) aluminum, you’d start around 125 amps.
Q: What is AC balance control?
A: AC balance control adjusts the amount of time the current spends in the electrode positive (EP) and electrode negative (EN) phases. Adjusting the balance affects cleaning action and penetration.
Q: Do I need a foot pedal for TIG welding aluminum?
A: While not strictly necessary, a foot pedal gives you much better control over the amperage while welding. This is especially important for aluminum, which is sensitive to heat input.
Q: What kind of gas do I need for TIG welding aluminum?
A: You should use argon gas for TIG welding aluminum. It provides a clean, stable arc and protects the weld from contamination.
Conclusion
Choosing the best aluminum TIG welder depends on your skill level, budget, and the type of projects you’ll be working on. The Lincoln POWER TIG 210 EXT offers a great balance of features and ease of use for both beginners and experienced welders. The AHP AlphaTIG 203Xi is a powerful and reliable option for those who need consistent performance. And for hobbyists on a budget, the Eastwood TIG 200 AC/DC is a solid choice. No matter which welder you choose, remember to practice and take your time to learn the nuances of aluminum TIG welding.
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