5 Common Myths About Welding Aluminum—Debunked!
When I came across a well-structured article in the latest issue of Welding Journal about aluminum welding and welding myths, I knew I had to share it.
Aluminum is a unique material—lightweight, corrosion-resistant, and highly conductive—but it comes with its own set of welding challenges. Over time, some misconceptions have been passed around, making it harder for welders, especially newcomers, to get it right. Let’s set the record straight.
One common myth is that GTAW (TIG) is the only way to weld aluminum. While GTAW does provide a clean, high-quality weld, GMAW (MIG) is also a great option, especially for thicker materials. Another misconception is that you must use a push-pull or spool gun for MIG welding aluminum. While these tools help with feeding softer wires, there are ways to weld aluminum using push-only torches with the right technique and wire selection.
Perhaps the most misleading myth is that pure aluminum (1100) filler works for all aluminum welding. In reality, filler metals need to be carefully matched to the base metal to avoid cracking. And despite what some old-school welders might say, 100% helium shielding gas isn’t necessary—argon-based blends offer great results at a lower cost. Lastly, the belief that you don’t need to remove anodized coatings before welding is false. The thick oxide layer interferes with arc stability, making proper cleaning essential.
American Welding Society
At the end of the day, understanding aluminum’s unique properties and using the right techniques will set you up for success. Whether you’re just starting or refining your craft, debunking these myths can help you achieve cleaner, stronger welds. Keep learning, keep welding, and always question what you hear in the shop!
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