The 4 Best TIG Welders for Aluminum – Reviews 2024

best tig welder for aluminum

Photo by Government of Prince Edward Island / CC BY

Tungsten Inert Gas welding, otherwise known as TIG welding, is the best means of welding aluminum. A TIG welder gives you more amperage, better overall cooling, and the precision and heat that is needed for aluminum. Unfortunately, TIG welding is also one of the more difficult forms of welding, requiring the use of both of your hands and most often an AC welder.

However, once one masters the art of TIG welding, there is no more efficient way of working with metals that require high temperatures to weld. Certain stick welders can be converted to TIG welders through the addition of an air-cooled torch and a bottle of argon. Here we have compiled a list of the 4 best TIG welders for aluminum on the market:

2018 AHP AlphaTIG 200X

The 2018 AHP AlphaTIG 200X is a top quality TIG welder that allows for the precise welder of thin metals. Aluminum, stainless steel, and just plain steel are all handled with ease by this great welder from AHP. It uses advanced inverter technology with pulse width modulation to give you the high performance that is needed to work with thinner materials and more precise projects. The design uses IGBT technology to give a reliable source of power and both 110V (with 150 amperage output) and 220V.  All standard TIG peripherals are fully compatible, although this welder does come with everything that you need to get started, straight out the box.

This highly affordable welder is a great option for those that want to get started with aluminum welding. The torch supplied is a type seventeen, although type 17, 18 and 26 are all interchangeable with this unit, as are most smaller torches, making this an exceptionally handy unit for light work. The pulse features match products that far exceed the cost of the 2018 AHP AlphaTIG 200X 200 Amp IGBT AC DC TIG/Stick Welder. For a square-wave inverter with TIG torch that includes an HF start mechanism so that you never struggle, look no further than this fantastic option from AHP tools.  It’s one of the best TIG welders for aluminum period.

LOTOS TIG200 200A AC/DC Aluminum TIG/Stick Welder

The LOTOS TIG200 200A AC/DC Aluminum TIG/Stick Welder is a fantastic, compact welder, whose dual-voltage functionality allows for precise, clean welding of aluminum. Carrying an adaptor allowing for use on both 220v and 100v, this welder with square-wave inverter is extremely versatile. It also gives you the option to either TIG or stick weld, matching professional users and infrequent DIY enthusiasts. This welder from LOTOS runs on oil-free argon, and is suited to all forms of metal, to a welding capacity of 1/4-inches.

Provided is everything that you need to begin welding, including a reliable high frequency hard torch control, as well as a much-needed foot pedal to adjust your heat on the fly. The LOTOS TIG200 has an excellent power efficiency rating of eighty percent. It is capable of a 60% duty cycle at 150 amps when powered at 110V, 220V gives a 60% duty cycle at 190 amps. Covered by a one year warrantee, this welder is durable, reliable and convenient, although slightly heavy at fifty-eight pounds.  For an industrial-quality unit that will provide years of reliable service, the LOTOS TIG200 is clearly one of the best TIG welders for aluminum available.

Hobart 500551 EZ TIG 165i 230-Volt

The Hobart 500551 prides itself as being one of the easiest to setup and use AC/DC TIG welders available. A unique single-knob control mechanism is featured, making it dead simple to set the materials that are being worked with and the thickness and operation mode. The AC welding functionality is fantastic for aluminum, while this welder from Hobart handles DC welds just as well. This unit is also capable of a non-contact, high-frequency start. One has the ability to control amperage completely, allowing for a great deal of fine tuning. Standard is a fan that only operated on-demand, when it needs to. This stops a great deal of debris from being sucked into the unit.

An automatic shutdown in terms of thermal overload protection keeps you unit safe in case of a malfunction.  The Hobart 500551 EZ TIG 165i 230-Volt Inverter-Based AC/DC Welder gives you precise control over every aspect of your welding, while at the same time remaining simple enough for the beginner. It is a very lightweight TIG welder that is capable of a lot. Remote foot control is also available to make things even easier. Included when shipped is the unit itself, a 12.5 ft. legacy 17 weldcraft TIG torch, a remote foot control, a 12 ft. working cable with fitted clamp, a shielded gas hose and a gas flow-meter and regulator.

TIG Welder, Precision TIG 225,208/230VAC

The TIG Welder, Precision TIG 225,208/230VAC is a professional stick and TIG welder giving you between five and 230 amps range. This fantastic TIG welder gives you stable, quick low-amp starting and excellent welding and cratering operation in either AC or DC welding mode. This welder from Lincoln Electric has an outstanding 100% duty cycle at 90 amps. When AC welding an auto-balance is active, optimally cleaning and configuring penetration levels, an excellent feature for aluminum welding.

The quality of construction of this Lincoln welder is nothing short of amazing. The pulse welding ability is excellent and the three way polarity selector is simple to use. The TIG Welder, Precision TIG 225,208/230VAC is an excellent unit that ships with everything that you need to start welding.  The only addition that is recommended is a large Argon tank (see a ton here).  If you can shell out the dough, bar none, this is the best TIG welder for aluminum on the market.

Aluminum Welding Tips

In terms of rod choice, a 4043 filler rod (see them here) is generally the best overall choice. It gives a good balance of cost and availability, as well as crack sensitivity. When welding aluminum, professionals often resort to a 50/50 mix of helium and argon; this technique appears to be the staple of the industry and should definitely be looked at. Any aluminum alloy must be extremely clean, no dirt whatsoever, so wipe the surface as cleanly as possible. It should also be noted that you will not get away with carrying out any bad habits brought from steel welding when working with aluminum.  It is extremely sensitive and meticulous precision is needed when welding.  Good luck!

  • Founder of Mechanical Caveman, Beau is an unrepentant tool enthusiast and, sporting deadlift-callused hands and an incongruous beer belly, all-around macho guy. When he doesn’t know re tools, he consults with his handyman and car-repairman buds to give you well-reasoned and cutting-edge info.

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