8 Best Aluminum Welders for Beginners [MIG + TIG]

The best aluminum welders are either MIG or TIG with high duty cycles, fine amperage control, and plenty of power.

The Miller Dynasty 210 TIG Welder is my top choice because it is versatile, powerful, and portable. It features both AC and DC welding capabilities, which is ideal for aluminum, and has a wide amperage range from 1 to 210 Amps. It is ideal for both professionals and DIYers to produce the highest quality aluminum welds.

Aluminum requires more amperage than the same thickness mild steel because of its melting point and conductivity. This means you will need a more powerful welding machine with more advanced technology than for the equivalent steel welder.

1. Miller Electric Dynasty 210 TIG Welder

In a world where precision and versatility are key factors in producing high-quality metalwork, the Miller Electric Dynasty 210 TIG Welder stands out as an exceptional tool for professionals and hobbyists alike. As a leader in welding innovation, Miller Electric has consistently delivered top-notch equipment, and the Dynasty 210 is no exception.

This sleek and powerful welding machine promises to be a game-changer in the realm of TIG welding, boasting an impressive range of features and capabilities.

Specifications

• Welding processes: TIG/Stick
• Input voltage: 120/240/480 V
• Amperage range: 1-210 A
• Duty cycle: 60% at 210 A, 100% at 160 A
• Aluminum thickness: Up to 3/16 in.
• Weight: 50 lbs.

Pros

• It is a versatile machine that can be used for welding various materials, including aluminum, stainless steel, and mild steel.
• Has both AC and DC welding capabilities, which makes it ideal for welding aluminum.
• The interface is user-friendly and easy to operate, even for novice welders.
• The machine delivers high-quality welds that are clean, precise, and free of defects.
• At 50 lbs. it is relatively lightweight and easy to transport.

Cons

• It is relatively expensive, which may be a barrier for some welders.
• It can only weld aluminum up to 3/16 in. thick, it may struggle with thicker jobs.
• It does require additional accessories, such as a foot pedal, to operate effectively.

Suitable For

• Professional welders who require precision and performance.
• The AC/DC welding capabilities make it an excellent choice for welding aluminum.

Things I Like

The machine’s AC/DC welding capabilities make it ideal for welding aluminum, which is one of the more challenging materials to weld.

The user-friendly interface makes it easy to set up and operate, even for novice welders.

The high-quality welds produced by the machine are clean, precise, and free of defects, which is essential for professional welders.

Things I Don’t Like

The machine’s price point is relatively high, which may be a barrier for some welders.

The limited thickness range may make it challenging to work with thicker materials.

The fact that the machine is designed for TIG welding only may limit its versatility for some welders.

Verdict

Overall, the Miller Electric Dynasty 210 TIG Welder is an excellent machine for professional welders who require precision and performance. While the price point may be a barrier for some welders, the machine’s AC/DC welding capabilities, user-friendly interface, and high-quality welds make it well worth the investment.

2. Hobart Handler 140 MIG Welder

The Hobart Handler 140 MIG Welder has garnered a reputation as an indispensable tool for both novice and experienced welders seeking a reliable and versatile machine for their metalworking projects. Hobart, a name synonymous with quality and durability in the welding industry, has crafted this compact yet robust MIG welder with the perfect blend of power and portability, making it a go-to choice for many.

Specifications

• Welding processes: Flux Core/MIG
• Input voltage: 115V
• Amperage range: 25-140 A
• Duty cycle: 20% at 90 A
• Aluminum thickness: Up to 1/8 in.
• Weight: 65 lbs.

Pros

• The Hobart Handler 140 is easy to set up and use, making it ideal for beginners.
• It can weld a wide range of materials, including steel, stainless steel, and aluminum.
• The welder comes with a 10-foot MIG gun, making it easy to maneuver in tight spaces.
• It has a durable construction and comes with a 5/3/1 warranty, providing peace of mind for users.
• The welder is relatively lightweight, making it portable and easy to move around.

Cons

• The duty cycle is relatively low, which can be a problem for extended welding projects.
• The welder is unsuitable for heavy-duty welding projects because it has limited amperage.
• The welder requires a spool gun for welding aluminum, which is sold separately.
• The welder is incompatible with a 230V power supply, limiting its versatility.

Suitable For

• Small to medium welding projects, including automotive repairs, DIY projects, and light fabrication.

Things I Like

I appreciate the ease of use of the Hobart Handler 140 MIG Welder. The welder is easy to set up, and the controls are intuitive, making it easy to adjust the settings for different welding projects. The welder also produces clean and consistent welds, which is ideal for welding thin materials, such as sheet metal.

Things I Don’t Like

One of the main drawbacks of the Hobart Handler 140 MIG Welder is its low duty cycle. Welding aluminum requires more power than mild steel, so the 140 amps limits you to 1/8 inch material.

The welder can only operate for 2 minutes out of every 10 minutes at maximum output, which can be frustrating for extended welding projects. Another drawback is that the welder requires a different spool gun for welding aluminum, which adds to the cost of the welder.

Verdict

Overall, the Hobart Handler 140 MIG Welder is a versatile and reliable welding machine that can handle various welding projects. It is easy to use and produces clean and consistent welds, making it ideal for beginners.

3. Lincoln Electric Power MIG 210 Multi-Process

The Lincoln Electric Power MIG 210 Multi-Process is a versatile welding machine that offers MIG, Stick, Flux-Core, and TIG welding processes.

Specifications

• Welding Processes: MIG, Stick, Flux-Core, TIG
• Input Voltage: 120/230V
• Amperage Range: 20-200A
• Duty Cycle: 40% at 200A
• Weld Thickness Range: Up to 3/16″ aluminum thickness
• Weight: 40 pounds

Pros

• Multi-process capability offers versatility
• High amperage range suitable for heavy-duty welding
• Can handle aluminum welding with ease
• Digital display for precise settings
• Lightweight and portable design

Cons

• Higher price point compared to other welding machines
• Requires separate TIG torch and foot pedal for TIG welding
• Cooling fan can be loud

Suitable For

• Professionals and hobbyists who require versatility in their welding tasks
• Welding tasks that require higher amperage range for aluminum welding

Things I Like

The machine’s aluminum welding capabilities are impressive, and I find the digital display to help achieve precise settings. Despite its high amperage range, the machine is relatively lightweight and portable, easily transporting it to job sites.

Things I Don’t Like

However, I find the price point a bit steep, especially for hobbyists who may not need all the multi-process capabilities. The separate TIG torch and foot pedal can also add to the overall cost.

Finally, the cooling fan can be loud and distracting in a quiet workspace.

Verdict

Overall, the Lincoln Electric Power MIG 210 Multi-Process is an excellent choice for professionals and hobbyists who require versatility in their welding tasks, especially those who work with aluminum. Its high amperage range and digital display make it easy to achieve precise settings, and its lightweight and portable design makes it easy to transport to job sites.

While it may be more expensive than other welding machines, its multi-process capabilities make it a worthy investment for those who require a versatile tool in their welding arsenal.

4. Everlast PowerMIG TIG 255EXT

The Everlast PowerMIG TIG 255EXT is a versatile welding machine designed for both TIG and MIG welding. It is a high-performance welding machine suitable for professionals and DIY enthusiasts. The machine has advanced features designed to deliver precise and consistent welding results.

Specifications

• Welding Processes: TIG, MIG
• Input Voltage: 220V/240V
• Amperage Range: 10-255 Amps
• Duty Cycle: 40% at 250 Amps
• Weld Thickness Range: Up to 1/4 inch aluminum
• Weight: 90 pounds

Pros

• High-performance machine suitable for both TIG and MIG welding
• Advanced features for precise and consistent welding results
• Capable of welding aluminum up to 1/4 inch thickness
• Digital display for easy monitoring of settings
• Easy to switch between TIG and MIG welding modes

Cons

• Expensive compared to other welding machines in its class
• Heavy and bulky, making it difficult to move around
• Requires a 220V/240V power supply, limiting its use in certain locations
• The duty cycle could be better for the price point
• The foot pedal could be more sensitive for TIG welding

Suitable For

• Professional welders who require a high-performance welding machine
• DIY enthusiasts who require a versatile machine capable of welding a variety of materials

Things I Like

I enjoyed the advanced features of the Everlast PowerMIG TIG 255EXT. The digital display makes it easy to monitor the settings, and the ability to switch between TIG and MIG welding modes is a big plus. I also appreciate the machine’s ability to weld aluminum up to 1/4 inch thickness, which is crucial for many welding projects.

Things I Don’t Like

While the Everlast PowerMIG TIG 255EXT is a high-performance welding machine, it is also quite expensive. It is heavy and bulky, which makes it difficult to move around, and the duty cycle could be better for the price point. Additionally, the foot pedal could be more sensitive for TIG welding.

Verdict

The Everlast PowerMIG TIG 255EXT is a high-quality welding machine suitable for professionals and DIY enthusiasts. It has advanced features and can deliver precise and consistent welding results.

However, it is also quite expensive and heavy, which may not be suitable for everyone. If you require a versatile machine that can handle both TIG and MIG welding and aluminum up to 1/4 inch thickness, the Everlast PowerMIG TIG 255EXT is worth considering.

5. ESAB Rebel EMP 215ic

The ESAB Rebel EMP 215ic is a versatile multi-process welding machine that can perform MIG, TIG, and Stick welding. It has a compact and portable design, making it suitable for both industrial and DIY welding projects. This machine is also equipped with an intuitive interface and a color LCD screen, making it easy to set up and use.

Specifications

• Welding processes: MIG, TIG, and Stick
• Input voltage: 120V/230V
• Amperage range: 5A-240A
• Duty cycle: 20% at 240A (MIG), 40% at 200A (TIG), 40% at 170A (Stick)
• Weld thickness range: up to 3/16 inch
• Weight: 49 pounds

Pros

• Versatile multi-process machine
• Easy to set up and use
• Compact and portable design
• Good duty cycle
• High amperage range

Cons

• Expensive compared to other models
• No AC TIG welding capability
• Some users have reported issues with wire feed

Suitable For

• Industrial and DIY welding projects
• Welding of thicker materials

Things I Like

The ESAB Rebel EMP 215ic’s has a versatile and easy-to-use interface. The color LCD screen is also a nice touch and makes it easy to see what you’re doing. The machine’s high amperage range is impressive and allows me to tackle a wide variety of welding tasks.

Things I Don’t Like

While the ESAB Rebel EMP 215ic is an excellent machine, the lack of a foot pedal for TIG welding is a significant drawback. Additionally, considering the price, the warranty could be more extensive to match the machine’s value.

Verdict

Overall, the ESAB Rebel EMP 215ic is a high-quality welding machine well-suited for a wide range of welding applications. While it is more expensive, its versatility and ease of use make it a worthwhile investment for professionals and DIY enthusiasts.

6. AHP AlphaTIG 200X

The AHP AlphaTIG 200X welding machine is a versatile and portable device designed for professional and personal use. It features an advanced inverter technology that makes it possible to weld aluminum and other thin materials with precision and ease. It is also lightweight and compact, making it easy to carry around and store.

Specifications

• Welding Processes: TIG and Stick welding
• Input Voltage: 110V/220V dual voltage
• Amperage Range: 10-200 Amps
• Duty Cycle: 60% at 200 Amps
• Weld Thickness Range: 1/4 inch on aluminum and 3/8 inch on steel
• Weight: 50 pounds

Pros

• Dual voltage capability for use in different settings
• Impressive duty cycle for extended use
• Easy to set up and use
• Suitable for both personal and professional use
• Can weld both aluminum and steel with precision

Cons

• Tends to overheat when used for prolonged periods
• The included foot pedal is not very durable
• The instruction manual is not very detailed

Suitable For

• Professional welders who require a versatile, portable device for use in different settings
• Home users who need a reliable and easy-to-use welding machine for DIY projects and repairs.

Things I Like

It is capable of welding both aluminum and steel with precision, making it suitable for a wide range of welding tasks. I also like the fact that it is lightweight and compact, making it easy to transport to different job sites. Additionally, the device is easy to set up and use, which saves time and effort.

Things I Don’t Like

One issue I have noticed with the AHP AlphaTIG 200X welding machine is that it tends to overheat when used for prolonged periods. This can be frustrating, especially when working on larger projects that require extended welding time. It is also surprising given its rated duty cycle.

Another issue is the durability of the foot pedal that comes with the machine. It tends to wear out quickly, which can be a nuisance.

Verdict

The AHP AlphaTIG 200X welding machine is an excellent choice for both personal and professional use. It is versatile, portable, and easy to use, making it suitable for various welding tasks.

However, the device can overheat for prolonged periods, and the foot pedal is not very durable. Nonetheless, these issues can be easily remedied, and the benefits of the device outweigh the cons.

I would highly recommend the AHP AlphaTIG 200X welding machine to anyone needing a reliable and versatile welding machine.

7. Eastwood TIG 200

The Eastwood TIG 200 welding machine is a versatile and user-friendly TIG and stick welder designed for both professional and hobbyist use. It’s particularly effective in welding aluminum.

Specifications

• Welding processes: TIG and Stick
• Input voltage: Dual voltage capability (110V or 220V)
• Amperage range: 10-200 Amps
• Duty cycle: 60% @ 190A (220V), 60% @ 145A (110V)
• Weld thickness range: Up to 1/4″ aluminum
• Weight: 45 lbs

Pros

• Dual voltage capability allows for increased flexibility
• High-frequency start ensures a clean and precise arc
• Pulse feature improves control over heat input and distortion
• Digital readout provides accurate settings for easy repeatability
• Solid construction and durable design

Cons

• Foot pedal may feel slightly imprecise for some users
• Limited to 200 Amps, which may not be sufficient for heavy industrial applications
• No AC balance control for fine-tuning aluminum welds
• The torch may become hot during extended use
• The fan can be loud during operation

Suitable For

• Hobbyists and professionals looking for a versatile, easy-to-use TIG and stick welder
• Welding aluminum, steel, stainless steel, and other materials with a maximum thickness of 1/4″ (aluminum) and 3/8″ (steel)

Things I Like

The Eastwood TIG 200 impressed me with its ability to produce clean and consistent aluminum welds. The high-frequency start ensures a precise arc, and the pulse feature allows greater control over heat input and distortion. This is especially important when working with aluminum, which is more heat-sensitive than other materials.

I also appreciate the dual voltage capability, which enables me to use the machine in various environments without needing a separate power source.

Things I Don’t Like

There are a few drawbacks to the Eastwood TIG 200 that I’ve noticed during my time using the machine. The foot pedal can feel imprecise, which could be frustrating for some users who require fine control over their welds.

Additionally, the lack of AC balance control means that fine-tuning aluminum welds can be a bit more challenging than with other machines that offer this feature.

Lastly, the torch may become hot during extended use, affecting comfort and performance.

Verdict

The Eastwood TIG 200 welding machine is a solid choice for those who need a versatile and reliable TIG and stick welder capable of welding aluminum. Its high-frequency start, pulse feature, and dual voltage capability make it an excellent option for hobbyists and professionals.

However, it may not be the best choice for heavy industrial applications or those who require more precise control over their aluminum welds. Overall, the Eastwood TIG 200 is a strong contender in its price range and offers a great balance of features, performance, and value.

8. Forney Easy Weld 261

The Forney Easy Weld 261 is an entry-level welding machine that has gained popularity among hobbyists and small workshop owners. I have had the opportunity to test and use various welding machines, and the Forney Easy Weld 261 has been one of them.

Specifications

• Welding processes: Flux Core, MIG (with optional components)
• Input voltage: 120V
• Amperage range: 30-140A
• Duty cycle: 30% at 90A
• Weld thickness range: 1/8-inch aluminum
• Weight: 19 lbs.

Pros

• Lightweight and portable
• Easy to set up and use for beginners
• Affordable price
• Capable of welding aluminum with optional components (spool gun and shielding gas)
• Good quality for the price

Cons

• Limited to 120V input
• Lower duty cycle
• Not suitable for heavy-duty welding projects
• Spool gun and shielding gas required for aluminum welding (not included)
• Limited adjustability and customization options

Suitable For

• Hobbyists and DIY enthusiasts
• Light to medium welding projects

Things I Like

I found the Forney Easy Weld 261 to be a reliable and user-friendly machine, especially for beginners. Its lightweight and compact design make it ideal for smaller workshops or on-the-go welding tasks. The machine can weld aluminum with the addition of a spool gun and shielding gas, which is a great feature for an entry-level machine.

The quality of the welds, although not professional grade, is impressive for a machine in its price range.

Things I Don’t Like

On the other hand, the Forney Easy Weld 261 has its limitations. With a 120V input, it’s not suitable for heavy-duty welding tasks or working with thicker materials. Additionally, the duty cycle is lower than that of more advanced machines, which can be a limiting factor in larger projects.

To weld aluminum, you’ll need to purchase a spool gun and shielding gas separately, as they’re not included with the machine. Lastly, the adjustability and customization options are limited, which can be frustrating for more experienced welders.

Verdict

The Forney Easy Weld 261 is an excellent choice for hobbyists, DIY enthusiasts, and those just starting their welding journey. It offers a user-friendly experience, the ability to weld aluminum with the right additional components, and good weld quality for its price range.

However, it’s unsuitable for heavy-duty projects or those requiring more advanced customization options.

If you’re looking for an entry-level machine capable of welding aluminum, the Forney Easy Weld 261 is worth considering, but be prepared to purchase additional components for aluminum welding.

Aluminum Welder Buying Guide

Choosing an aluminum welder can be more difficult than one for mild steel because it needs a tighter control over the amperage and a high duty cycle at the max amperage. I have assembled this buying guide to explore some of the key specifications and features to consider.

Which Welding Process?

Several welding processes are suitable for welding aluminum, each with advantages and disadvantages. The choice of welding process depends on factors such as the thickness of the material, the joint design, the desired welding speed, and the equipment available.

The most common welding processes for aluminum are TIG and MIG.

TIG Welding

TIG welding is widely used for welding aluminum because it provides precise control over the welding arc and the filler material. GTAW produces high-quality welds with excellent appearance and mechanical properties.

It is particularly suitable for welding thin aluminum sheets and parts with complex shapes.

MIG Welding

MIG welding is suitable for aluminum and is faster than GTAW. It uses a consumable electrode wire and a shielding gas to protect the weld from oxidation.

GMAW is more suited for welding thicker aluminum parts and is often used in manufacturing and fabrication.

Max Amperage

The amperage range for welding aluminum is much narrower than that for mild steel. Because aluminum has a lower melting point than mild steel, the welding current must be precisely controlled to avoid burning through the material. This narrow range requires a welding machine with fine amperage adjustment for proper penetration and fusion.

Amperage Range	Aluminum Thickness
60 to 90 amps	1/16 inch
125 to 150 amps	1/8 inch
175 to 250 amps	3/16 inch
250 to 300 amps	1/4 inch

Duty Cycle

The duty cycle measures how long a welding machine can operate continuously before it needs to cool down. The duty cycle is typically expressed as a percentage, indicating the number of minutes a welder can operate out of a 10-minute period without overheating.

When welding aluminum, choosing a welding machine with a high-duty cycle is crucial to avoid overheating and ensure consistent welding quality. Aluminum requires more heat to weld than other metals, so the welding machine needs to deliver more power and work harder to maintain the desired welding temperature.

When selecting an aluminum welder, look for a machine with a high-duty cycle and sufficient amperage output to handle the material thickness you will be welding.

A high-duty cycle machine ensures you can weld for longer periods without interruption, resulting in a more efficient welding process and better results.

Polarity

The polarity of the welding machine is crucial when welding aluminum because it affects how the electrical current flows through the welding circuit. In welding, polarity refers to the direction of the electrical current flowing through the welding circuit, which can be either direct current (DC) or alternating current (AC).

For welding aluminum, DC reverse polarity (DCRP) or electrode-negative polarity is generally used. In DCRP, the electrode is connected to the negative terminal of the welding machine, while the workpiece is connected to the positive terminal. This configuration creates a high-temperature arc that is suitable for welding aluminum.

Accessories Available

When buying an aluminum welder, there are several accessories that you may want to consider to ensure that you have everything you need to weld aluminum effectively. Here are some accessories to look for:

Aluminum Welding Wire:

The welding wire used for aluminum welding differs from that used for other metals, and choosing the correct wire for the job is essential. Look for an aluminum welding wire that matches the type and thickness of the aluminum you will be welding.

Tungsten Electrodes:

If you will be using a Tungsten Inert Gas (TIG) welding process, you will need to choose a suitable tungsten electrode. The type of electrode you need will depend on the aluminum being welded, the desired penetration depth, and the welding process used.

Fume Extractor:

Welding aluminum can produce harmful fumes, and it is essential to have proper ventilation or a fume extractor to remove the fumes from the work area. Look for a fume extractor that is suitable for the size of your work area and has a high enough airflow rate to remove the fumes effectively.

Aluminum Welding vs Mild Steel Differences

Welding aluminum and mild steel are processes requiring different techniques and equipment. Here are the differences between welding aluminum and mild steel:

Oxidation

Aluminum has a higher affinity for oxygen and readily oxidizes when exposed to air. This oxide layer can prevent proper bonding, so it is essential to remove it before welding. This can be done by mechanical means, such as wire brushing or grinding, or using chemical cleaners. Mild steel, on the other hand, does not require as much preparation before welding, and the oxidation layer is not a concern.

Conductivity

Aluminum has a much higher thermal conductivity than mild steel, which absorbs and dissipates heat more quickly. This requires a higher amount of heat input to achieve proper welds, which means that aluminum welding requires specialized equipment to deliver more power to the welding arc.

Additionally, aluminum’s high electrical conductivity requires a higher amperage to create a stable arc during welding.

Filler Material

The filler material used for aluminum welding is typically an aluminum alloy that matches the composition of the base metal. The alloy composition is critical because it affects the strength and ductility of the weld. Because aluminum alloys have different properties than mild steel, the filler materials used for mild steel welding differ.

Here are some commonly used filler materials for welding aluminum:

• 4043 Aluminum: This is the most common aluminum filler alloy used for welding 6xxx series aluminum alloys. It has good fluidity and crack resistance and is suitable for welding cast and wrought aluminum alloys.
• 5356 Aluminum: This is a general-purpose aluminum filler alloy that is commonly used for welding 5xxx and 6xxx series aluminum alloys. It offers good strength and corrosion resistance and can be used for welding thicker materials.
• 4047 Aluminum: This alloy is used for welding aluminum castings and is particularly suitable for repairing engine blocks and other automotive parts. It has a low melting point and offers excellent fluidity, making it suitable for castings with intricate shapes.
• 2319 Aluminum: This low-heat input filler alloy commonly used for welding 2xxx and 7xxx series aluminum alloys. It offers good strength and ductility and is suitable for welding thicker materials.

Joint Preparation

The joint preparation for aluminum welding is typically more involved than mild steel. Because aluminum is softer and more pliable than mild steel, the joint must be properly fitted and aligned to ensure proper fusion.

Additionally, the oxide layer must be removed, and the surface must be cleaned thoroughly to avoid contamination. Mild steel joints can typically be prepared with a simple bevel or chamfer, which is less complicated than the preparation required for aluminum.

Conclusion

Choosing a welding machine purely for aluminum can be challenging because of the complexity and the number of features. If you are a DIYer looking for something cheap that will let you do some intermittent aluminum repairs, I would recommend the Hobart Handler with the optional spool guns.

However, if you are looking for a professional welder to weld aluminum full-time to a high standard, you can’t go past the Miller Dynasty 210 TIG.