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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.
One advantage of using a stick/MIG machine with DC current to weld aluminum is that itâs fast, says Jim Harris, senior product manager for TIG equipment at Lincoln Electric. What you sacrifice is precision and appearance.luminum TIG requires gas shielding just like MIG (only 100-percent argon), a specialized tungsten-tipped torch, AC current and a foot pedal to vary the heat and current. The tungsten tips of TIG torches get very hot. Some use air cooling but TIG welding above 200 amps typically requires a water-cooled torch.