Welding Tips and Tricks

Hi all,

My name is James Marler. I am a 48 year old Mechanical Engineer that stated a side business about 10 years ago making metal art. I have worked my way into business signs over the last couple of years. I am not a welding professional - didn't even start until 2000 - and still learning alot.

Just purchased an Eastwood Digital TIG 200 AC/DC machine so that I can weld aluminum specialty signs - and am having the usual issues learning to weld aluminum - devil in the details.

Anyway - look for me on the forum looking for direction on Aluminum AC welding of .063" sheet - trying to get the best welds I can.

Welcome. You might find it easiest to weld that thinner material with 4047 wire, not 4043 as the ‘47 has a lower melting point. You will likely have to order that wire online since most local welding stores don’t carry it readily. And stick to 1/16” wire with a 3/32 light blue tungsten. You’ll still need some amps to weld it, but a foot pedal to control and taper the heat off will help greatly.

Personally, for thin ally, I would have bought a Spool gun capable welder. Easier and faster to MIG thin ally than to TIG it. But an AC/DC TIG is a nice to have for all around work.

Biggest issue is that I didn't want the weld to show through to the front of the panel. Trying to layer signs like this with 1.5 to 3 inch spacers between the layers with minimal sanding after. Basically - I'm lazy...
Thanks for the tips on the Tungsten and 1/16 rod, will get that on order. Sent from my SM-P600 using Tapatalk