How to Weld Aluminium to Aluminium: TIG, MIG, Filler Metals & Alloy Guide
Aluminium possesses distinct physical and metallurgical properties—including a tenacious refractory oxide layer that melts at 2,072°C, thermal conductivity five times higher than structural steel, extreme liquid hydrogen solubility, and a lack of visible color change before melting. Successful aluminium-to-aluminium welding requires matching the base alloy series to an appropriate process (AC TIG, pulsed MIG, or SMAW) and compatible filler metal while designing for unavoidable heat-affected zone softening.