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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.
Shielding Gas and Cost-effective Joining. Shielding gas selection is critical to achieving cost-effective joining of carbon steel, stainless steel, and aluminum. You can select one gas, such as argon for aluminum welding, to provide suitable arc stability, minimum spatter, and good bead shape.