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A 115-volt welder can handle aluminum up to an eighth of an inch thick (3 mm) with adequate preheating, and a 230-volt machine can weld aluminum that's up to a quarter of an inch thick (6 mm). Consider a machine with an output greater than 200 amps if you will be welding aluminum daily.
However, when people started to aluminum GTAW using alternating current (AC), they found out thoriated electrodes really werenât well-suited for that type of welding. In AC GTAW, much more energy is taken up by the tungsten than is taken up in DCEN welding. In the past the electrode choices were limited to pure tungsten or zirconiated tungsten, which could carry more current than a pure tungsten electrode of the same size.