Best Welder for Aluminum (TIG / MIG) with Reviews

Top 3 Picks

Pressed for time? Check out our top picks

best overall rating★★★★★

Hobart 500559 Welder

Hobart 500559 Handler 140 MIG Welder 115V
  • Easy to use
  • Great value for money
  • Great for beginners
best overall rating★★★★★

AHP AlphaTIG 200X

2018 AHP AlphaTIG 200X 200 Amp IGBT AC DC Tig/Stick Welder with PULSE 110v 220v 3 YEARS WARRANTY
  • Great aesthetic appeal
  • Good value for money
  • Bang for the buck
best overall rating★★★★★

Lotos TIG200ACDC Welder

Rheem RTE 13 Electric Tankless Water Heater, 4 GPM
  • Stable welding arc
  • Deep arc pool
  • Great aesthetic appeal

How We Decided: 27 products considered. 900+ reviews analyzed, 29 research hours spent, 25+ info. sources referred

Aluminum is the most complex material for welding. Because of its great electricity conductivity, it has to be welded more quickly than steel, while requiring almost three times the current.

Also, since the current is much stronger, electrodes will have to be cooled in water. This guide will help you out in choosing the perfect aluminum welder for you.

Top Welders for Aluminum Compared

Product SpecificationsPrice
Hobart 500559 Handler 140 MIG Welder 115VHobart 500559 MIG Welder
  • Volts: 115V
  • Amp: 200 A
  • Type: MIG
2018 AHP AlphaTIG 200X 200 Amp IGBT AC DC Tig/Stick Welder with PULSE 110v 220v 3 YEARS WARRANTY2018 AHP AlphaTIG 200X
  • Volts: 110V/220V
  • Amp: 200 A
  • Type: TIG
Lotos 200A AC/DC Aluminum TIG/STICK ARC Welder, Square Wave Inverter, 110/220V Dual Voltage, BrownLotos TIG200ACDC Welder
  • Volts: 110/120V, 220/240V
  • Amp: 200 A
  • Type: TIG/Stick
LOTOS MIG175 175AMP Mig Welder (2 Versions - With or W/out Spool Gun) Both Include Mask, Solid wires, Argon Regulator, Standard MIG GunLOTOS MIG175
  • Volts: 220/240V
  • Amp: 175 A
  • Type: MIG
LOTOS MIG140 140 Amp MIG Wire Welder, Flux Core & Aluminum Gas Shielded Welding with 2T/4T Switch Argon Regulator, Metal Wire Feeder, Black/RedLotos 140 Amp MIG Wire Welder
  • Volts: 110/220V
  • Amp: 140 A
  • Type: MIG
Hobart 500554001 Handler 190 with SpoolRunner 100Hobart 500554001 Handler 190
  • Volts: 230V
  • Amp: 190 A
  • Type: MIG
Lincoln Electric Square Wave TIG 200 TIG Welder, K5126-1Lincoln Electric TIG 200
  • Volts: 110/220V
  • Amp: 200 A
  • Type: TIG
Hobart 500551 EZ-TIG 165i AC/DC TIG Welder 230VHobart 500551 EZ-TIG 165i
  • Volts: 230V
  • Amp: 165 A
  • Type: TIG
LINCOLN ELECTRIC CO K2697-1 Easy MIG 140 Wire Feed Welder,LINCOLN ELECTRIC CO K2697-1
  • Volts: 120V
  • Amp: 140 A
  • Type: MIG
MTS-205 205 Amp MIG/TIG-Torch/Stick Arc Combo Welder, Weld Aluminum(MIG) 110/230V Dual Voltage Welding NewAmico MTS-205 Welder
  • Volts: 110V/230V
  • Amp: 205 A
  • Type: MIG/TIG-Torch/Stick
Lincoln Electric POWER MIG 210 MP Multi-Process Welder Aluminum One-Pak - K4195-1Lincoln Electric POWER MIG 210 MP
  • Volts: 120V/230V
  • Amp: 210 A
  • Type: TIG/Stick
Welder, MIG/Flux Core, 120V, 90A @ 18.5VDC<Miller Electric, 907612
  • Volts: 120V
  • Amp: 140 A
  • Type: MIG

Reviews of the Best Welder for Aluminum

1.best overall rating

Hobart 500559 MIG Welder

Hobart 500559 Handler 140 MIG Welder 115V

Hobart offers a lot of different welder models and this particular welder can work smoothly on aluminum along with a wide range of other metals like brass, titanium, copper, cast iron, magnesium.

The welder requires the standard voltage level of 115 V to operate.

The welder weighs 65 lbs and it is fitted with a cast aluminum drive system of industrial grade.

Check out the features of this aluminum welder in a quick video.

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • Capable of welding 24 gauge up to 1/4 in. of mild steel
  • Range of the wire feed speed is 40 – 700 IPM and 50 – 740 IPM at no load
  • Voltage controller offers five-position selector for a smooth and stable arc

Pros

  • Easy to use
  • Great value for money
  • Great for beginners
  • Rated well for versatility
  • Very compact and portable
  • Made in the USA
  • Highly recommended by users

Cons

  • Hobart quality control should be better
2.best overall rating

2018 AHP AlphaTIG 200X

2018 AHP AlphaTIG 200X 200 Amp IGBT AC DC Tig/Stick Welder with PULSE 110v 220v 3 YEARS WARRANTY

Along with aluminum, this welder is also effective at welding mild steel. The welder offers a dual voltage mode for operations. This means that it can be operated at 110 V or 220 V depending on the welding requirements of the user.

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • Makes use of the advanced inverter technology
  • Maximum weld thickness in aluminum is 1/4″
  • Maximum weld thickness in mild steel is 3/8″
  • PWM (pulse width modulation) used with IGBT technology
  • Can work on stainless steel as well other thin gauge metals
  • Features an HF start TIG
  • Includes a foot pedal for great control
  • Weighs 69 lbs

Pros

  • Great aesthetic appeal
  • Good value for money
  • High accuracy and welding precision offered
  • Technical support is easily accessible
  • Great machine that works as advertised
  • Bang for the buck

Cons

  • Warranty terms could be better
3.best overall rating

Lotos TIG200ACDC Welder

Lotos 200A AC/DC Aluminum TIG/STICK ARC Welder, Square Wave Inverter, 110/220V Dual Voltage, Brown

This Lotos welder is specifically designed for aluminum welding and is a 200 AMP AC inverter (square wave) for the same. The maximum rated amperage output is 200 A (AC/DC).

Apart from aluminum, it can also work on stainless steel or other thinner gauge metals.

The power efficiency rating of this welder is 80%. The torch is an HF start model. The welder also offers a foot pedal for precise welding control.

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • Striking current is completely adjustable
  • Fitted with the German technology Papst Advanced Cooling System
  • Dual voltage and dual-frequency input (110/120 V, 220/240 V; 50/60 Hz)
  • Backed by a one year manufacturer’s warranty
  • Weighs 58 lbs
  • Offers TIG and STICK welding options
  • Maximum weld thickness is 3/8″ (9.5mm) for mild steel, stainless steel, and aluminum

Pros

  • Stable welding arc
  • Deep arc pool
  • Kit includes all the necessary equipment
  • Good value for money
  • Great aesthetic appeal

Cons

  • Some users found the controls a bit confusing
4.best overall rating

LOTOS MIG175 Mig Welder

LOTOS MIG175 175AMP Mig Welder (2 Versions - With or W/out Spool Gun) Both Include Mask, Solid wires, Argon Regulator, Standard MIG Gun

The welder is fitted with a high-quality aluminum wire feeder for smooth operations. As the name suggests, the welder has an output amperage capacity of 175 A.

The kit of the welder includes a spool gun (high-speed) which is well-suited for aluminum welding.

The welder can work with an input voltage of 220/240 V.

Check out the features of this welder in a quick video.

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • Maximum welding thickness for aluminum is 3/16″
  • Reliable and durable transformer performance
  • Welding thickness range for mild steel is 18 Gauge – 1/4″
  • Weighs 85 lbs
  • Backed by a one year warranty offered by the manufacturer

Pros

  • Kit includes all the required accessories
  • Easy to set up within 10 minutes
  • Can operate with the 4 inch or 8-inch wire spools
  • Good value for money
  • Reputed brand

Cons

  • Replacement parts are hard to find
5.best overall rating

Lotos 140 Amp MIG Wire Welder

LOTOS MIG140 140 Amp MIG Wire Welder, Flux Core & Aluminum Gas Shielded Welding with 2T/4T Switch Argon Regulator, Metal Wire Feeder, Black/Red

The notable feature of this welder is that it offers dual modes of operation. The 2T mode is manual which allows great control over the welder settings and therefore is good for the more experienced welders.

The 4T mode is semi-automatic which means that the settings are automatically adjusted to some extent and this is a great help to the novice welders.

Check out the features of this welder in a quick video.

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • Welding voltage and wire speeds are highly adjustable
  • Works with the standard 110/120 V voltage outlet
  • Kit includes ground clamp, gas hose, MIG torch, welding mask and wire
  • Comes with two digital displays
  • Weighs 54 lbs

Pros

  • Variable welding thickness for different materials
  • Reliable aluminum wire feeder
  • Great transformer technology
  • Quick connector for ground cable
  • Can work with 4-inch and 8-inch wire spools
  • Good for novice users

Cons

  • Some users felt that the heat output was not sufficient
6.best overall rating

Hobart 500554001 Handler 190

Hobart 500554001 Handler 190 with SpoolRunner 100

This aluminum welder by Hobart is a part of their Handler series. Apart from aluminum, the welder can also successfully weld steel in the thickness range of 24 gauge to 5/16in.

The company claims that the welder is capable of giving powerful and professional results. The voltage input needed to operate this welder is 230 V.

Check out the specifications of this aluminum welder in a quick video at:

 

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • Output amperage is in the range of 25 A to 190 A
  • 30% duty cycle @ 130 Amps
  • Offers the user seven different voltage selections
  • Fine control over parameters ensures less spatter
  • Weighs 89 lbs
  • Designed and manufactured in the USA

Pros

  • Easy to set up and use
  • Can handle higher power welding requirements
  • Fitted with a selector switch to choose between gun and spool
  • Offers great portability
  • Excellent value for money
  • Highly recommended by the users

Cons

  • Warranty terms could be better
7.best overall rating

Lincoln Electric TIG 200

Lincoln Electric Square Wave TIG 200 TIG Welder, K5126-1

As the name suggests, this particular welder model by Lincoln Electric makes use of the square wave inverter technology for efficiently welding aluminum.

The features that are offered by this welder are advanced yet it is very easy to use.

It is one of the best TIG machines for aluminum welding. It also offers the stick mode from the same power source. The welder weighs 72 lbs.

Check out the unboxing video of this aluminum welder at:

 

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • Great use for hobbyists as well as small craftsmen
  • Maximum cutting thickness is 3/8″ on 110v and 1/2″ on 220v for steel
  • Offers HF start for aluminum and steel
  • Features a digital display for easy settings

Pros

  • Works well even for large fabrication projects
  • Reliable performance delivered
  • Good value for money
  • Component quality is good

Cons

  • The pulse feature is limited to 20 PPS
8.best overall rating

Hobart 500551 EZ-TIG 165i

Hobart 500551 EZ-TIG 165i AC/DC TIG Welder 230V

Hobart is a well-known brand in the welding equipment market and this model is well-suited for beginners as the settings are extremely easy to configure.

The interface is easy to use as after powering on the machine, one has to select only the material and the thickness and forget about the rest.

The fan that is fitted inside the welder runs only on demand and this helps to reduce the slag or debris that may get pulled into the machine.

Check out the features of this aluminum welder in a quick video at:

 

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • The maximum weld thickness is 22 gauge up to 3/16 in. for aluminum (AC and DC)
  • HF start eliminates material and tungsten contamination
  • Great precision control over the amperage
  • Weighs 60 lbs
  • Uses a light-weight inverter-based technology
  • Single knob control for ease of use

Pros

  • Easy to use
  • Fitted with a foot pedal
  • Portable welder for small jobs
  • Good customer support service

Cons

  • Product life could be longer
9.best overall rating

LINCOLN ELECTRIC CO K2697-1

LINCOLN ELECTRIC CO K2697-1 Easy MIG 140 Wire Feed Welder,

This MIG welder by Lincoln Electric is good for welding aluminum. The maximum output amperage for this device is 140 A.

Check out the features of this aluminum welder in a quick video at:

 

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • Maximum welding thickness for aluminum is 22 gauge to 10 gauge
  • The maximum welding thickness for mild steel is 24 gauge to 3/16 In.
  • Output amperage varies in the range of 30 A to 140 A
  • 20% duty cycle at 60 Hz and 20 input amps

Pros

  • Handheld portable welder
  • Can be used for gas and gasless welding
  • Highly recommended by customers
  • Reliable performance
  • Long-lasting product life

Cons

  • Should come with an instruction manual
10.best overall rating

Amico MTS-205 Welder

MTS-205 205 Amp MIG/TIG-Torch/Stick Arc Combo Welder, Weld Aluminum(MIG) 110/230V Dual Voltage Welding New

Apart from aluminum, this welder can be used in a wide variety of materials like stainless steel, mild steel, cast iron, copper, etc. to name a few.

It offers the TIG as well as the STICK option for welding. The device can work well with solid, flux core or aluminum wire.

It has a very clear wire melting droplet transfer feature. The output amperage for this welder lies in the 10 A to 205 A range.

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • Advanced IGBT technology used
  • Wave-form control system
  • Clear arc ignition and less spatters
  • The wire feeding mechanism is of high quality
  • Overload and overcurrent protection
  • Automatic temperature control technology
  • Good amperage control
  • Weighs 25 lbs

Pros

  • Very lightweight
  • Great for DIY projects
  • A high ease of control
  • Good value for money
  • Kit includes all the necessary accessories

Cons

  • Manual could be better written
11.best overall rating

Lincoln Electric POWER MIG 210 MP

Lincoln Electric POWER MIG 210 MP Multi-Process Welder Aluminum One-Pak - K4195-1

This aluminum welder by Lincoln Electric is a multi-process welder that allows for TIG and flux-cored welding. It is extremely lightweight at just 40 lbs and packs a load of features.

The notable feature about this welder is that it is operable at the dual voltage modes of 120 V or 230 V. This allows one to easily plug it into any power supply.

Check out some videos about the user interface, TIG and stick setup and screen protector replacement.

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • Controls are intuitive push-and-turn designed
  • Large colored displays available
  • Advanced settings are easy to set and access
  • Includes a Magnum Pro spool gun
  • Fitted with an all-metal wire drive

Pros

  • Customers found it easy to use
  • High versatility offered
  • Good brand reputation
  • Excellent value for money
  • Good warranty terms
  • Excellent customer support
  • Great and simple to understand features

Cons

12.best overall rating

Miller Electric, 907612

Welder, MIG/Flux Core, 120V, 90A @ 18.5VDC

This Miller Electric welder model works best at welding aluminum and along with that, the other materials that it can work on are stainless steel and mild steel.

Some of the key USPs of this aluminum welder are listed below.

Key USPs

  • The maximum welding thickness for mild steel is 24 gauge to 3/16 In.
  • Maximum welding thickness for aluminum is 14 to 18 gauge
  • The maximum welding thickness for stainless steel is 20 gauge to 1/8 In.
  • Fitted with quick select drive rolls
  • 20% duty cycle at 20 amps, 60 Hz
  • Output amperage is in the range 30 A to 140 A DC
  • Weighs 64 lbs

Pros

  • Customers happy with the product performance
  • Easy to use the welder
  • Good for hobbyist and light welding projects
  • Good brand repute

Cons

Buying Guide

Hobart 500554001 Handler 190 with SpoolRunner 100

There are a few things that you should look for when choosing a welder for aluminum. Let’s take a look at some of these to help you make your purchasing decision.

AC or DC Operation

Firstly, you should consider the AC and DC operation. Most professionals, when welding aluminum, usually like to use AC (alternating current).

For example, when welding with a direct current reverse polarity, a cathode cleaning of the oxide film happens. The result is significantly increased welding temperature.

The fact is that even the material of which the electrode is made will start to break down. If you connect a direct current straight polarity, then it won’t break but will provide a more stable arc.

As you can see, just switching between the polarities of the current will result in a significant difference in your work.

For more information about AC vs DC operation, watch this video: 

Output Power

Also, you should pay attention to the output power, which is measured in amperes. Basically, the rule says that the higher the power is, the thicker materials you can weld.

When buying a welder, you should always look at the amperes. You should buy the one that offers the largest range of power output, at the best price.

If the range is small, it will drastically limit the types of materials that you can weld. A welding machine with a large amperage is usually more expensive.

At the same time, it is a great investment since it will allow you to weld a variety of materials, without the need for another welder.

Arc Stability

Another important thing to note is that the welder should have good arc stability when welding below 10 amperes. This way, you will have significantly better control over the released heat while welding.

Heat Control

Heat control is a very important feature of a high-quality welding machine since heat control reduces metal deformation while welding thin metals. Pulse welding is a great way to control heat while welding.

While pulse welding, the machine will switch between the full and low current, which will hold the arc while at the same time, the torch head can cool down.

Duty Cycle

A duty cycle is another important feature to consider. Basically, it shows how long you can work continuously in a cycle of ten minutes.

The fact is that if you work longer than the recommended time, the welding machine can heat up, and therefore the electric circuits will melt.

For example, some low-quality welding machines will have a duty cycle of 10%, which means that you can weld for a total of 1 minute in a period of 10 minutes.

Some TIG welding machines have a duty-cycle of about 50-80%, which is an incredible difference.

Price

In the end, a price should be considered as a very important factor when buying a welding machine. Prices can range between $600 and $4000, but for a good TIG welding machine, you might need to spend more than $3000.

Also, note that most of the welding machines should have a warranty of at least 3-5 years.

FAQs

What kind of welder is used for aluminum welding?

Usually, both TIG and MIG welding can be pretty good for aluminum welding. They use pure argon for aluminum materials of thickness up to ½-inch.

What type of electrode is best for aluminum?

Since aluminum welding is different than steel welding, a different electrode should be used. The best choice seems to be Lanthanated electrodes, because they provide a stable arc and clean weld, with both AC and DC welding.

What is the best tungsten for aluminum?

For aluminum welding, TIG Welding Tungsten Electrodes 2% Lanthanated seems to be the best choice. You should also check out GENSSI TIG Welding Tungsten Electrode 175mm, which is often used by professionals.

Can I weld steel to aluminum?

Basically, you can weld aluminum to most of the metals. However, if you want to weld aluminum to steel, you should implement special techniques that are not well-known to beginner welders. For more information about this, check out this video.

Summary

These are the most important things to consider when buying an aluminum welder. However, one of the most important things is the output power, but if you are frequently welding, you should also pay attention to the duty cycle.

After all, be sure to buy a welder that offers a wide range of power output, so that you will never need another welding machine.

Here are our top picks, again for you –

  1. Hobart 500559 MIG Welder
  2. 2018 AHP AlphaTIG 200X
  3. Lotos TIG200ACDC Welder
  4. LOTOS MIG175 175AMP Mig Welder
  5. Lotos 140 Amp MIG Wire Welder
  6. Hobart 500554001 Handler 190
  7. Lincoln Electric TIG 200
  8. Hobart 500551 EZ-TIG 165i
  9. LINCOLN ELECTRIC CO K2697-1
  10. Amico MTS-205 Welder
  11. Lincoln Electric POWER MIG 210 MP
  12. Miller Electric, 907612

Last update on 2020-10-21 / Affiliate links / Images from Amazon Product Advertising API

Jason Brown
About Jason Brown

Jason is a DIYer who loves to weld and experiment with various welding techniques. A pet lover and a hardcore vegan, he contributes to topics related to welding techniques, reviews, and guides.

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