Best Welders For Aluminum

As an operator, to weld aluminum requires a whole new level of expertise if you agree with me.  Aluminum alloy provides more headaches and presents more challenge to welder operators than steel alloys. This is mainly because of the softness of the aluminum feeding wire.

Beginning with its base metal preparation and choosing what welding guns to make use of. It is always important to clean the base material to remove any aluminum oxide and hydrocarbon contamination from the cutting solvents. Preheating the aluminum work piece is also important in avoiding the welding cracking.

A lot of things come into consideration when it comes to choosing the best welders for aluminum, however, It is important to note that when it comes to aluminum welding, it is important to take note of the push technique being used, the travel speed, the shielding gas, the power source, the wire feeder and so on. However, choosing a welding method for aluminum depends more on what you’re applying the welding to as well as the skill set the welder possesses.

Top 7 Welders For Aluminum

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There are three types of aluminum welder methods and they include

TIG Welders: this is the most common and primary method of welding aluminum. Although it requires a lot of heat to get the temperature up, in the end it makes it all worth the wait because of its capability to hold the heat. They work well for both thin aluminum sheets and thicker aluminum plates.

MIG Welders: this is known as metal inert gas welding. When choosing a MIG welder, you must make a pre-informed decision based on your skill sets as to whether you would opt for spray arc welding or pulse welding methods. The later requires an inverter supply while the former uses constant current/voltage.

Torch Welders: This is a highly difficult method in terms of control of heat; its mode of operations requires using a gas-fed torch.

In general, when choosing the best welders for aluminum, you need to consider not just the technique you’re equipped with, but also the materials used for producing the welders and of course the price you have to pay for these welders.

We have taken time to test run various welders for aluminum to see which of these machines are actually worth going all out for. And we have been able to narrow down the best welders for aluminum to 7. Check them out below.

  1. Hobart 500559 Handler 140 MIG Welder 115V

This welder right here is absolutely phenomena and arguably the best welder for aluminum out there. I’m sure if you’re quite familiar with welders, you would realize there has been an ongoing talk about the Hobart 500559 being the best welder for aluminum ever made so far. Well here is why this welder lives up to its hype. It’s not just about its versatility that makes it able to perform extremely well at not just residential works, but also at an industrial level. The Hobart 500559 handler is built to utmost quality and durability, one which welder operators have been demanding for a while.

Hobart 500559 Handler 140 MIG Welder 115V

The Hobert Handler uses a MIG Installation method and with a 20% duty cycle then you could actually weld 2 minutes out of 10 minutes. Usually the less the amps you weld at, the higher the duty cycle. This welder plugs into a regular wall outlet  and the 140 amp is the highest you can go before you go to 220 plug.

I really cannot speak more highly of a better 140 welder. If you’re looking to weld aluminum then this right here is your catch even at a professional level, this Hobart has what you need. I use it with 75% Argon and love it. The Hobart 500559 operates with a 115V from a standard household current and the wire feed speed Rage is 40-700IPM at load, but at no load it feeds at 50-740IPM.

More importantly, the Hobart Handler does not have restrictions to aluminum it can be used to weld trailer frames, farm equipment, body panels etc. this phenomenal welder for aluminum doesn’t give you any sort of stress when assembling together. It is very easy to set up and all you need to do is follow the instruction that comes with it. The Hobert handler definitely deserves top spot on our list of best welder for aluminum

Pros
  • The welder is easy to set up
  • The welder can weld a lot of materials and be used for both residential, industrial and commercial welding
  • The Hobert Handler comes with a built-in storage
Cons
  • Comes with no safety gear
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 Now let’s take a look at the 2018 AHP AlphaTIG 200X 200 Amp IGBT AC DC Tig/Stick Welder that comes really close to the Hobert Handler.

  1.  2018 AHP AlphaTIG 200X 200 Amp IGBT AC DC Tig/Stick Welder

Speaking of the best welder for aluminum out there, this right here truly deserves to be the runner up to our favorite welder the Hobert Handler. Here is why it is such a close competitor. Unlike the Hobert Handler, the 2018 AHP AlphaTIG 200X 200 Amp IGBT AC DC Tig/Stick Welder is a TIG welder which I can boldly tell you provide an easy avenue for you to weld aluminum. This welding machine can hold heat for a very long time and can be applied to both thin aluminum sheets and thicker ones.

This is a top quality Tungsten inert gas welding machine for aluminum, stainless or steel that gives a very precise welding of thinner-gauge materials.

2018 AHP AlphaTIG 200X 200 Amp IGBT AC DC Tig/Stick Welder with PULSE 110v 220v 3 YEARS WARRANTY

The manufacturers really did a good job on this with the upgrade from older versions. This particular machine is upgraded with an IGBT technology which is an advanced Inverter Technology with Pulse Width Modulation that allows you to convert high voltage easily and also gives you control over the current. This really puts you in a commanding position to avoid overheating of the aluminum work piece. The  2018 AHP AlphaTIG 200X 200 Amp IGBT AC DC Tig/Stick Welder requires a separate filler rod, and you should always choose a welding rod with an alloy close to that of the workpiece as much as possible.

To be honest this is more of a professional welder for aluminum and might require some level of expertise. But just as our number one best welder for aluminum, this alpha series is one of the most versatile and durable welding machines you can get out there at such an affordable price   

Pros
  • The 2018 AHP AlphaTIG welder is very easy to Control
  • The welder is engineered with advanced power modules
  • It is a professional welder that is highly versatile
Cons
  • The pedals might be up to standard as the Hobert Handler in our top spot
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  1. Lotos TIG200ACDC 200A AC/DC Aluminum Tig Welder with DC Stick/Arc Welder, Square Wave Inverter with Foot Pedal and Argon Regulator 110/220V Dual Voltage Brown

The Lotos TIG200ACDC 200A AC/DC Aluminum Tig Welder is the third second TIG welder on our list and has everything it takes to be among the top three welders for aluminum. This machine is specially engineered to give comfort and ease in welding stainless steel and aluminum.

Although it has fewer features when compared to our top two on this list, The Lotos TIG200ACDC 200A AC/DC Aluminum Tig Welder  really does a good job in welding aluminum. This a welder perfect for not just professionals but generally if you are looking to weld some aluminum while getting an industrial quality out of it, then this might be just the welder you need to purchase for that.

It can be easily controlled to give so much accuracy in welding because of its square wave inverter while being able to perform in varieties of situations.  Its super control abilities are also because it is designed with a start hand torch control and a precise foot pedal welding heat control. Just as our top two on the best welder for aluminum, this welder has such versatility which makes it worth being in our top three.

Lotos TIG200ACDC 200A AC/DC Aluminum Tig Welder with DC Stick/Arc Welder, Square Wave Inverter with Foot Pedal and Argon Regulator 110/220V Dual Voltage Brown

This particular package comes with a 1/16″ thoriated tungsten, cup, collets, collets body, tig torch, ground clamp, and stinger. It is engineered with a dual voltage of 110V/220V 50/60Hz which you can easily switch between voltages with so much ease and control.

This dual voltage capability allows the machine to run directly on 220V 50/60Hz power or 110V 50/60 Hz with the use of a pigtail. But not just that, the The Lotos TIG200ACDC 200A AC/DC Aluminum Tig Welder is capable of running on two different voltages with two different frequencies. Here you are getting a welding machine that is 80% efficient.

Overall I am very impressed and happy with the quality of the welder and its welding capacity which is 3/8″ (9.5mm) for mild steel, stainless steel and aluminum as it will produce and function just as you would want it to and one would be getting the value for your dollar! This whole machine really cost less than expected.

Pros
  • This welder is Suitable for welding not just aluminum but also stainless steel, mild steel and other metal materials
  • The Lotos TIG200ACDC 200A AC/DC Aluminum Tig Welder is specialized in TIG welding
  • The welder Provides accurate heat control ad advanced cooling
  • It is dual voltage and frequency welding machine
  • It is highly power efficient with an 80% efficiency
Cons
  • Regulators are a little bit not up to standard when compared to the Hobart Handler series
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  1. ZENY Arc Welding Machine DC Inverter Dual Voltage 110/230V IGBT Welder 160 AMP Stick

As a beginner in this process of welding and still trying to figure out what welder suits you best as a starter, well you must have been wondering and probably scrolled past our top three because they come up as welders for aluminum made for professionals.

Well I’ve got your back with this amazing welding machine: the ZENY Arc Welding Machine DC Inverter Dual Voltage 110/230V IGBT Welding machine. Such a beauty made absolutely to fit in for beginners in this business.

This welder right here gives you so much comfort and convenience, you can take it around easily everywhere you might need it. Extremely portable and designed to be the most compact of all welders for aluminum.  Its versatility is definitely one of the best things about this welder.

ZENY Arc Welding Machine DC Inverter Dual Voltage 110/230V IGBT Welder 160 AMP Stick

Besides aluminum, it fits a lot of metal materials of different thickness. It can be used on surfaces of stainless steel, mild steel etc. although,  the ZENY Arc Welding Machine DC Inverter Dual Voltage 110/230V IGBT Welder is an Inverter welders that switches AC power to DC which would need you to then incorporate a step down transformer to produce the proper voltage and current. This welder gives a dual voltage with a 60% duty cycle running at 115 and 230V which is pretty easy to control.

Running at about 220V, I think this welding machine is much better suited for welding steel up around 1/4″ in thickness, with its ample power being capable of building a cargo trailer for road use. However, for an average welding around home I think this unit would be far better and more versatile

This welder is really easy to use, it is designed with an infinite amperage control with an LED meter so you can set the machine to your required settings which makes it suitable for both industrial and residential purposes such as machinery manufacturing, sheet metal processing, construction field, automotive maintenance and other industrial large projects. But not just that, the welder can easily be a perfect fit for home users.

The package comes with extra features such as Electrode holder and 6.4ft. cable, Work clamp and 5 ft. cable, Input power adapter cable & plug and overall If you are an absolute beginner to welding and you need something that’s very convenient to carry anywhere you need, then you should consider the ZENY Arc Welding Machine and this really could be the best 100 bucks you have ever spent.

Pros
  • Easy to use and set up
  • Durable and high-quality materials
  • Good price for high quality
Cons
  • The ZENY Arc Welding Machine requires compressed air to operate
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  1.  LOTOS MIG175 175AMP MIG Welder

Although not in our top three welders for aluminum, this machine is very well known among experts in welding and also highly recommended. LOTOS MIG175 175AMP MIG Welder is designed perfectly not just for MIG professionals but also for beginners In welding. This welder comes with a lot of features that makes it perfect for welding. It arguably has everything you might be looking for in a welder.

First let's talk about how this welding machine is designed with a stable and quality wire feeder, which as a welder is extremely important when you want to overlay the filler metal accurately. This product offers you just that which makes your welding experience more enjoyable.

LOTOS MIG175 175AMP Mig Welder with Free Spool Gun, Mask, Aluminum Welding Wires, Solid Wires, Argon Regulator, Standard MIG Gun

More importantly it comes with a high-speed MIG spool gun for aluminum welding, which is 10 feet 4 inches long, with a 4-prong end connection, 1lb aluminum wire, and 0.9 millimeter, making it perfect for welding a 3/8 inch or thinner aluminum plate.

These features are very essential for all MIG welders to make welding less of a headache. Other extremely important materials that come with this welding machine includes Torch, Argon Regulator, Gas Hose, welding musk, Wire.

Versatility is also something we considered before including this welding machine in our list, as well as its ease of use. The welder can easily be connected to your existing 220V wall outlet and can be set up quickly within 10 minutes. However, if you are using this welding machine with a generator, the welder requires 30AMP Under 220V. So your generator should be larger than 7000 Watt

Pros
  • The welder is very easy to operate
  • It is relatively cheap and affordable for the functions it offers
  • High quality performance while ensuring durability
  • The welder comes with all necessary equipment you need to start welding
Cons
  • Motor driver can be very loud
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  1. VIVOHOME Portable Flux Core Wire No Gas MIG 130 Welder Machine 110V Yellow

This welder machine is engineered with top quality materials that gives it such level of durability, keeping it from rusts and corrosion. One of the beautiful features of this machine is its ease of control of both speed and current. Depending on what you are cutting through, or material surfaces you are working with,  it has 10 levels of adjustable speed that makes it adaptable to all cutting needs as well as the flow of the current being easily controllable, this makes this this welding machine applicable to a variety of different materials such as aluminum, mild steel, stainless steel and other metallic materials.

VIVOHOME Portable Flux Core Wire No Gas MIG 130 Welder Machine 110V Yellow

The VIVOHOME Portable Flux Core Wire No Gas MIG 130 Welder Machine is designed with two air vents that help heat dissipation and reduce operation temperature.

To be honest this model is not quite popular among household users but it does a really good welding Job and would recommend it based on its price in relation to what it has to offer.

It is actually a very good welding machine for beginners, As with any other beginners friendly welding machine among the best welders for aluminum, this unit is compact and weighs just 37.1 pounds with a handle of its own, making it really easy to move about. The machine has a two power switch for amp output combinations up to 120A 20VDC and a 1 -10 speed control dial for the wire feed.

Pros
  • The welder offers great value for your money
  • It has an adjustable wire feed speed control
  • The welding machine is a perfect fit for most homes because it works with a standard 110V power outlet
  • It is very portable
Cons
  • It operates only with DC

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  1. SUNGOLDPOWER 200Amp MIG MAG ARC MMA Stick DC Welder 110/220V Dual Voltage IGBT Inverter 200A Aluminum Welding Soldering Machine Gas

The last on the list is the SUNGOLDPOWER 200Amp MIG MAG ARC MMA Stick DC Welder which without no doubt has all it takes to be on the top 7 welders for aluminum. This welding machine is a dual voltage machine which can be easily switched and controlled from 110v or 220v power sources.

This feature makes it a perfect match for professional and industrial projects.  This MIG welder seems very well built and comes with almost everything you need to wield (flux core)

SUNGOLDPOWER 200Amp MIG MAG ARC MMA Stick DC Welder 110/220V Dual Voltage IGBT Inverter 200A Aluminum Welding Soldering Machine Gas Shielded/Gasless Flux Cored Wire Solid Core Wire Welding Equipment

The SUNGOLDPOWER 200Amp MIG MAG ARC MMA Stick DC welder has adjustable wire feed speed and welding current, you can adjust it to suit your application and weld with different thicknesses which Ideal for home uses such as using with rusty metal. This is also a very versatile welding machine Suitable for welding not just aluminum but also stainless steel, mild steel, aluminum, and other metal materials.

Pros
  • The welding machine works with a dual power outlet It has a duty cycle of 60%
  • It is highly versatile
  • The machine produces very little splatter
Cons
  • The flux core wire is too thick to fit the machine
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Conclusion:

Whatever you do when choosing your welder for aluminum, you have to be careful not to get swayed away by the prices. You might also need to ask yourself what works best for you between an MIG. TIG and flex core welders. We have discussed varieties of the top welder for aluminum and out there, and really for both industrial and residential purposes, you should now possess all you need in choosing the best welder for aluminum.