Can aluminum be welded with an electric welding machine?

Among the many metals used today, aluminum stands out for its lightness, durability, good thermal conductivity, and high corrosion resistance. But precisely because of these characteristics, welding aluminum is not easy. Many people – especially those new to the mechanical field – have wondered: Can aluminum be welded with an electric welding machine? The short answer is yes, but the key lies in using the right type of machine and the right technique. Let Kenta Vietnam explain this in more detail.

Why is welding aluminum not simple?

If you have ever welded iron or steel, you will find it quite easy to operate and with few errors. But with aluminum, it's different. Aluminum conducts heat extremely quickly – 4 to 5 times faster than steel – so the temperature in the welding area is often dispersed, making melting difficult. In addition, the surface of aluminum always has a thin but stubborn oxide layer, which has a higher melting point than pure aluminum. If this oxide layer is not thoroughly treated before welding, the weld will be prone to porosity, cracking, or even not sticking together.

And there's another factor: aluminum is soft, easily deformable, and expands significantly when exposed to high temperatures. So, if you don't control the current and operating speed well, you can easily cause the part to warp, burn at the edges, or even be completely damaged.

So, can aluminum be welded with an electric welding machine?

Despite these challenges, welding aluminum with an electric welding machine is entirely feasible – as long as you use the right machine and the right method. Among the types of electric welding machines, not all are suitable for "befriending" aluminum.

TIG welding machines (non-consumable electrode arc welding) are considered the most suitable for welding aluminum. Thanks to their ability to precisely control the current, use non-consumable tungsten electrodes, and combine with protective Argon gas, TIG machines allow for beautiful, clean, and durable aluminum welds.

In addition, MIG welding machines are also quite commonly used in industrial production when fast welding speed and high productivity are required. However, to effectively weld aluminum with MIG, you need to equip suitable welding wire, precisely adjust the wire feeding speed, and control the Argon gas well. Otherwise, the weld will be prone to gas porosity or unevenness.

Conversely, stick welding machines (SMAW) – the most common type in households or small workshops – are not the optimal choice for welding aluminum. Due to the lack of protective gas and low current control capability, welding aluminum with a stick welding machine can easily cause errors, waste material, and not ensure the mechanical properties of the product.

Suitable welding materials cannot be chosen randomly

Choosing the right type of machine is not enough. Choosing the welding wire or welding rod is equally important. Depending on the technical requirements, you can consider the following types:

• ER4043 welding wire (AlSi5): This is a very common type of wire for 6xxx series aluminum alloys. Easy to use, bright welds, and less cracking, suitable for beginners or those who need aesthetics.
  
• ER5356 welding wire (AlMg5): Often used in marine, automotive, or structural industries requiring high strength. However, this wire requires good technique to avoid hot cracking.
  
• Aluminum welding rods: Used with TIG welding machines, effectively filling and beautifying welds. Suitable for thin parts requiring high aesthetic appearance.
  

And importantly: whether using wire or rod, you need to use pure Argon protective gas. This is a key factor to prevent the weld from oxidizing, reduce porosity, and increase durability.

Where to buy aluminum welding materials to ensure quality?

Once you are ready to start your aluminum welding project, the next thing you need is a reputable material supplier. At Kenta VietNam, we specialize in distributing ER4043, ER5356 aluminum welding wires, and technically standard TIG welding rods, with full CO-CQ certification, reasonable prices, and dedicated technical consultation.

Whether you are a beginner or a seasoned engineer, the Kenta team is always ready to assist you in choosing the right type of wire/rod for each practical application.

Need quick consultation or a quote? Contact Kenta VietNam now for detailed support!