As many welders can attest, welding aluminum is a different ball game than welding steel. With its low melting point but high thermal conductivity, aluminum can go from solid to liquid very quickly, catching both beginners and seasoned welders off guard during the welding process. Practice definitely helps when welding aluminum, but proper material prep and the right equipment can significantly ease that steep learning curve.

Familiarizing Yourself with Aluminum’s Differences

For welders who are used to handling steel, aluminum can accurately be described as a material that’s the complete opposite. It’s lighter, softer, and has a lower melting point (approximately 1200°F), which means that once it heats up, it can stay hot and easily lead to burn-through. It also requires pure 100% argon (or an argon/helium mix) for arc stability — another significant departure from what’s used for steel.

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