Comparative characteristics of popular aluminum welding machines: features, pros and cons, price

Due to its chemical and physical properties, welding of aluminum structures is carried out differently than welding of steel, stainless steel and other metals. To ensure that the seams are strong and even, and the aluminum alloy construction is reliable, special technologies are used. In particular, specialists often use an argon welding machine for aluminum. And since aluminum alloys are characterized by strength, low weight and high resistance to corrosion, the combination of such qualities has made it possible to use them in many industries: aircraft construction, shipbuilding, the automotive industry and others. Aluminum in its pure form, without impurities, has very little strength and its application is of a slightly different nature. It is rarely used in the manufacture of structures, only in the food and electrical production cycles, where it is used for the manufacture of molds and packaging. Welding aluminum is complicated by its low melting point, so during work there is a high probability of burning through the workpieces.

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Triton ALUMIG 200 SPULSE SYNERGIC

Photo: https://beru.ru

A welding machine that supports MIG and MAG welding. This ensures high-quality welding of aluminum and its alloys. Device capabilities: gas purging of the welding zone, there are several cycles (at the beginning and at the end). The convenient “Burn Back” function allows you to set the device for a specific wire annealing time. Triton ALUMIG 200 SPULSE SYNERGIC welding machines are used for welding aluminum and its alloys, as well as for welding stainless steel. So if you don’t yet know which machine to use to weld aluminum, then take a closer look at this model.

Welding machine Triton ALUMIG 200 SPULSE SYNERGIC

Advantages:

• reliable
• good service life
• powerful

Flaws:

• not detected

Features and difficulties of aluminum welding

Aluminum welding may be necessary to seal a crack in the engine oil pan or gearbox. This is often how a damaged engine cooling jacket block is repaired this way. Aluminum welding machines are in demand in the chemical and food industries, in the manufacture of containers, collectors, filters and other products.

But aluminum and its alloys AlMn, AlSi, AlMg are less weldable due to the main feature - the presence of a refractory oxide layer on the surface. Its melting point is 2044 degrees, while the metal underneath it flows after 660 degrees. This is a major problem because the low current is unable to melt the outer layer and the filler metal is deposited on the surface. High current strength leads to through burns. Therefore, classical technologies are not suitable for aluminum welding.

Other difficulties in working with this metal include the following:

• Small difference between melting and freezing temperatures. Aluminum becomes fluid at 660 degrees. But if you let it cool by only 15-20º C, then it already begins to crystallize. An aluminum welding machine is required that can maintain the operating current in such a range that a seam can be formed.
• Increased thermal conductivity. Heat spreads through aluminum 5 times faster than mild steel. The weld pool cools quickly, and the part can become significantly warped over a large area even from a small seam.
• Preservation of color in molten form. When welding ferrous metals, it is easy for the welder to control the condition of the weld pool and the amount of additive supplied, since it becomes dazzling white, in contrast to red slag. Aluminum does not change color in liquid form and it is more difficult for the welder to visually understand how well the seam is formed.
• Increased shrinkage. After cooling, the deposited beads of metal can sag significantly, which forms pits in the weld and requires repeated surfacing from above.
• Interaction with the external environment. Upon contact with ambient air, aluminum evaporates hydrogen, which leads to large pores in the weld structure. Such a connection will not withstand the pressure of water or other liquid. It is necessary to protect the weld pool from external gases.
• Increased fluidity. In the molten state, aluminum is similar to water - it is more difficult to direct the liquid metal with a torch, especially when making a weld in an inclined plane. This also leads to accelerated through-burns.

The first welds of novice aluminum welders are always bad. Gradually, the problem is solved by training in practice. But the correct choice of a welding machine designed for joining aluminum is of paramount importance here.

Triton ALUTIG 200P AC/DC

​Photo: https://beru.ru

This aluminum welding machine has a convenient MIX/TIG function. Thanks to this, it is possible to use a special mode when welding aluminum alloys, which will ensure high-quality penetration of metals with different thicknesses - tig welding of aluminum. The welding machine is convenient both at a construction site and in the garage. Aluminum welding occurs without beads. What is very important, the Triton ALUTIG 200P AC/DC machine has a low gas consumption and allows, among other things, aluminum spot welding.

Welding machine ALUTIG 200P AC/DC (TIG, MMA)

Advantages:

• easy to use
• powerful
• reliable

Flaws:

• not detected

Argon arc welding machines

When working with aluminum and its alloys, it is best to choose a method such as argon arc welding.

The technology of joining metals under gas protection (argon or helium) allows you to make a seam “clean” of oxides. Argon simply displaces atmospheric air from the welding zone and the metal crystallizes in its pure form.

However, in addition to protection, additional processes are used to destroy the oxide film. Most often, this is the use of non-consumable tungsten electrodes with appropriate current settings or semi-automatic welding.

Let's consider each of these types of devices separately.

Manual argon arc (TIG) welding

Until recently, such equipment was only available in industrial settings.
Today, thanks to the development of production, such devices are available to everyone and at a low cost. What is such a device? The most common are welding inverters with the ability to connect gas equipment.

The device can be used in the usual configuration for electric arc welding, but by connecting a torch with an argon supply and a tungsten electrode, it turns into equipment for aluminum welding. In addition, appropriate adjustments are needed to configure the device to work with such material.

An aluminum welding machine must have the following capabilities.

• Function of increasing the starting current (presence of an oscillator). In an argon atmosphere, the arc either ignites poorly or does not ignite at all. Doubling the starting current solves this problem.
• Precise settings of the main current, which is adjusted in accordance with the thickness of the workpieces. If the indicator is low or too high, the metal is not welded or burned through.
• Gas supply regulation. To ensure a high-quality connection of aluminum parts, set the required argon flow rate (about 10-12 liters). You will also need a so-called gas supply after welding, when the metal hardens in protection.

These are the main functions that a device for welding “winged” metal in manual mode should have.
The positive qualities of argon arc welding equipment are:

• Argon displaces air and does not allow aluminum to oxidize, while it itself does not react with the metal.
• The use of non-consumable electrodes significantly reduces the amount of smoke and slag. The seam is much easier to clean.
• Very high quality connection of aluminum parts.
• Precise settings of the device allow welding of workpieces that are too thin.
• There is virtually no deformation of parts, since strong heating occurs only in the cooking zone.

The negative aspects include relatively expensive equipment and consumables (gas, tungsten, and filler wire). But at the same time, you can weld any aluminum products in your home workshop.

Semi-automatic TIG equipment

Semi-automatic welding machines have also relatively recently become available to the common user.
The work is based on feeding wire, which melts the metal and melts itself, forming a seam. To work with aluminum, such devices also have the function of connecting an argon supply to displace air from the cooking zone.

However, in addition to the protective atmosphere, such devices have another advantage - the pulsed operating principle.

The wire is fed by a mechanism into the weld pool, its tip is melted under the influence of the arc and a drop of molten metal is formed. At this moment, an increase in the impulse creates pressure under which a particle of the melt is pressed into the surface.

This pulse welding allows you to get a better quality seam compared to other types of equipment.

A semi-automatic welding machine with the possibility of tig welding must have the following functions.

• As with manual welding, gas supply equipment must be connected to the semi-automatic welding machine.
• Such a device must also be precisely adjusted to the appropriate current and polarity.
• Be sure to set the wire feed speed and gas flow rate.
• The presence of an oscillator to increase the initial current strength, allowing you to ignite an arc in an argon atmosphere.

Semi-automatic aluminum welding offers many advantages, even compared to manual argon arc welding.

• You can weld very thin aluminum billets (0.5 mm thick).
• The weld seam is of very high quality, smoother and without sag.
• The welding wire has the necessary additives and additives to enhance the strength characteristics of the connection.
• During operation, less smoke and fumes are generated, and the seam is not contaminated with slag.

One of the negative qualities is the rather expensive cost of all equipment. Also, to work with such welding, you need experience, and a beginner will need to initially learn the techniques and techniques for welding aluminum with a semi-automatic machine.

However, semi-automatic tig welding remains the best equipment available for home workshops today.

Aurora РRO INTER TIG 200 AC/DC РULSE

​Photo: https://beru.ru

A good welding machine for tig welding aluminum and alloys. Its special feature is remote control via a small remote control. The device can be used for both TIG and MMA welding, and with any types of electrodes. In general, Aurora PRO INTER TIG 200 AC/DC PULSE welding machines are distinguished by their productivity and welding quality. Among the advantages, we should highlight not only high performance, but also versatility. Thanks to the presence of a pulse mode, the inverter can be used as a welding machine for stainless steel and aluminum.

Welding machine Aurora PRO INTER TIG 200 AC/DC PULSE

Advantages:

• control via remote control
• qualitative
• powerful
• multifunctional

Flaws:

• price

Types of welding for working with aluminum

Differences in the properties of aluminum and other metals have led to the emergence of a number of features when creating permanent structures. Aluminum parts can be connected using one of three types of welding:

• MIG;
• TIG (AC);
• MMA.

The most common of the methods listed above was and remains TIG or manual arc welding. It is used for joining products made of aluminum and alloys based on it for critical purposes. Despite the fact that the welding speed with this method is 4 times lower than with the other two, this cannot be called a disadvantage. The proof is the result, namely a high-quality and neat welding seam, and an almost complete absence of pores.

Watch the video, MIG and MMA welding:

The parts are connected using piece electrodes of reverse polarity. In this case, general or local heating of the product is carried out to a temperature of 250°C. After welding, the edges must be cleaned of oxides and contaminants, and the slag must be removed with steel brushes and washed with hot water. This method is also called argon-arc welding, but this is not entirely correct, since the following is used as a shielding gas:

1. Helium;
2. Nitrogen;
3. Mixtures.

aluminum welding and its features

The advantages of TIG welding include the following characteristics:

• Neat seam;
• Ability to control arc parameters;
• No splashing;
• Work on small arc togas.

However, only an operator with extensive experience can connect parts using this method.

The MIG welding method involves the use of a semi-automatic welding machine and is based on the use of solid melting wire. Moreover, the unit must be pulsed, equipped with special settings for working with aluminum.

Watch the video, TIG (AC) welding:

This method is considered the most productive. For this, an inverter power supply is used, which produces a base current and a short-term pulse current of large values. This operating mode allows you to control the transfer of metal droplets from the electrode to the product. A special feature of pulse welding is the wire feeding by rollers of a special mechanism.

The disadvantage of this method is considered to be the insufficient density of the deposited metal and the presence of pores in the welds. Therefore, it is not very popular, losing out to TIG welding.

REAL TIG 200 P AC/DS

​Photo: https://beru.ru

A special feature of this welding machine is the ability to weld at a low voltage of 160 Volts. The device has several operating modes 2T/4T to ensure high-quality pulse welding. Therefore, REAL TIG 200 P AC/DS welding machines are very popular. Their only drawback is that in the 2T operating mode it is not possible to weld the crankcase.

Welding machine PRO TIG 200 P DSP AC/DC (E201) (TIG, MMA)

Advantages:

• low voltage welding
• several operating modes
• popular brand

Flaws:

• there is no possibility to weld the crater

Welding aluminum at home

When welding aluminum material at home, it is not always possible to create the required conditions for the work. However, it is often necessary to repair aluminum structures at home, but the process will certainly be accompanied by difficulties. After all, a “volatile” metal does not change color when heated. Therefore, the contractor will not be able to visually determine whether the material has been heated sufficiently, whether the joint has been “sealed,” or whether it is necessary to continue home welding of aluminum.

If it is not possible to use TIG or MMA technology at home, use a gas burner:

• propane - a special or multi-purpose device with automatic ignition and gas saving option;
• acetylene - the device is used with disposable or stationary cylinders for soldering with soft or refractory solder;
• for MAPP gas, it is a high-performance tool, since the fuel in the form of a gas mixture releases more energy during combustion compared to propane.

This method involves melting the metal using the thermal force resulting from the use of gas energy. The process itself is not complicated and requires a small amount of funds. Moreover, it is the most affordable for welding aluminum at home.

The combustion of gases allows one to reach the required temperature for melting the metal. Due to this, sections of 2 parts are welded together. The connecting element is aluminum wire. The use of gas allows you to reliably protect areas of 2 elements in comparison with the coating that covers the electrodes.

When working with aluminum, flux is also used to improve the weld. It is most often used during gas welding of thick aluminum. Flux helps remove metal oxide. It contains low-melting alkaline substances, chloride compounds and a small percentage of fluoride elements. Flux can be in the form of a powder or paste.

The process of joining aluminum blanks is performed in the following sequence:

1. After preparing the areas to be welded, flux is laid out, which improves the fluidity of aluminum and the quality of the seam.
2. The workpieces are heated when using a burner. This will allow the solder to melt and flow.
3. The filler material is brought to the joint and the seam is filled with solder, melted under the temperature of the flame.
4. After completing gas welding of aluminum, it is necessary to wait time so that the created joint has time to cool. Then a quality check of the seam is performed.

Before welding aluminum with a torch, you should always check the equipment used. Particular attention must be paid to the integrity of the hoses and gas cylinder, which should be located no closer than 5 m from the work site.

Popular gas burners

FoxWeld MT-55 is an Italian tool for heating various metals. The torch is suitable for working with refractory solders. The device is equipped with piezo ignition and flame regulator. It is used with disposable cans, on which it is secured using a collet connection.

STURM is a Russian instrument with piezo ignition. The main purpose of the double seal nozzle is to solder metal objects. The device has high wear resistance and good ergonomics.

Stayer 55584 is a German tool used in the construction and repair of aluminum structures. The device is equipped with piezo ignition and a collet clamp for connecting to cans. The device allows you to smoothly change the size of the flame and is small in size and weight.

TESN TIG 200 P ACDC (E101)

​Photo: https://beru.ru

The device has the ability to purge with gas before and after welding, as well as a short-term supply of pulsed current, which greatly facilitates the possibility of exciting the welding arc. One of the advantages is the presence of a pulse welding mode with the ability to regulate the pulse frequency. There is also the already popular AC/DC welding mode with the ability to adjust the current increase over time. Welding machines for aluminum have found wide application in auto repair shops. Among the disadvantages, a large number of settings should be noted, so that an untrained welder can easily get confused.

Welding machine TECH TIG 200 P AC/DC (E101) (TIG, MMA)

Advantages:

• gas purging
• pulse welding mode
• powerful
• reliable

Flaws:

• Difficulty in management and configuration

Some features of aluminum and its alloys

Aluminum differs from other metals in its high thermal conductivity, chemical reactivity and low specific gravity. A welding machine for aluminum must work quickly and protect the weld pool well . Conventional equipment for metal structures and body welding will not be able to provide conditions suitable for welding aluminum.

Aluminum oxidizes quickly even when cold at room temperature. The oxide film formed on top is much harder than the base metal and melts at 2000⁰C, which is 2 times higher than the melting point of aluminum itself. Part of the strength of lightweight duralumin parts is provided by a hard film of aluminum oxide. When mechanically stripped to bare metal in the open air, the oxide film is restored very quickly.

Aluminum has a high coefficient of linear expansion when heated. If the parts are overheated, they will be severely warped.

High thermal conductivity contributes to the rapid spread of heat throughout the body of the part and the same almost instantaneous cooling of the seam, when the slag has not yet come out.

Triton ALUMIG 250Р Drulse Synergic 380v

​Photo: https://beru.ru

Among the available features of this model, we should highlight the presence of a special technology called “Soft Switch”, which protects this model of the device from overheating and strong current surges. The welding machine also has a so-called “Hot Start” mode. Thanks to this, preheating of aluminum welding equipment is not required. Well, the presence of 2T/4T modes with the ability to fill a crater makes the welder’s workday significantly easier.

Welding machine ALUMIG 250P Dpulse Synergic 380v (MIG/MAG)

Advantages:

• protection against overheating and current surges
• hot start
• easy to operate
• powerful
• reliable

Flaws:

• not detected

Welding machine design

Complete set for argon welding

Structurally, such equipment consists of the following components and mechanisms:

• Gas cylinder and hose;
• Cassettes with wire, mechanism and pipeline for its supply;
• Burners;
• Batteries;
• Control unit.

The operation of the device for welding aluminum is as follows: gas enters the arc and thereby protects the product from oxidation. To supply it, a semi-automatic welding torch is used. They are equipped with a handle made of insulating material.

Welding unit design

It contains:

• Start button;
• Shield.

The torch package includes a nozzle and a tip for supplying current. The ceramic materials used in its manufacture are designed to protect the nozzle from sticking of molten metal.

Elements made of copper-graphite alloys are used as tips. They allow you to ensure high-quality contact. The torch is connected to the welding machine in one of two possible ways: a connector or a solid connection. The functions of the power source in the device can be assigned to a transformer or inverter. Not only the dimensions, but also its price depend on which of the listed devices is used. Welding inverters are most widely used, as they are lightweight and easy to transport and operate.

Various welding methods

Wire feeding in a semi-automatic welding machine for welding aluminum is carried out in various ways:

1. Pushing;
2. Pulling;
3. Combined.

The first one is considered the most common. It is carried out using a drive located in the body of the device. The combined method usually uses both pulling and pushing mechanisms. Moreover, they are used for long sleeve lengths.

The wire used in welding machines can be:

• Steel;
• Made of stainless steel;
• Aluminum.

Wert SWI 190 (TIG, MMA)

​Photo: https://beru.ru

Wert is one of the best welding machine companies. The SWI 190 model is universal, works using TIG and MMA technology. The power of the device is small - 3.5 kW, but it is inexpensive. The highest current strength is 190 A. Thanks to its compactness and lightness (weight less than 2.5 kg), the device is valued by installers performing high-altitude work. Useful options include hot start, protection against electrode sticking, and the ability to adjust arc force.

Welding machine Wert SWI 190 (TIG, MMA)

Advantages:

• light weight
• cheap model
• Arc force can be adjusted

Flaws:

• low power

Welding Features

Despite the low melting point, joining aluminum using an open flame (electric arc) is a complex process:

1. Light metal at high temperatures (over 1000°C) easily enters into a chemical reaction with oxygen in the air and begins to burn actively. In addition, it begins to react with nitrogen and carbon dioxide.
2. The oxide film is a refractory substance. The change in the state of aggregation begins at 2050-2100°C. The flowing mass is instantly replaced by newly formed aluminum oxide.

In the process of joining aluminum workpieces, the direct current strength drops, which causes a decrease in temperature - the preconditions are created for the intensive restoration of the refractory protective film. The result is a violation of the quality of the seam, a deterioration in strength. Welding with alternating current allows you to reduce the negative effect to a minimum. When passing through “0,” intense heat generation occurs on the surface of the part. The temperature rises, melting (destroying the protective cover) the oxide film.

ELITECH AIS 220 Prof (TIG, MMA)

​Photo: https://beru.ru

Due to its high power rating (7.4 kW) and versatility, the model can be classified as a semi-professional level device. The welding machine is designed for long-term non-stop operation at normal and reduced voltage. For ease of control, it is equipped with a digital display with precise adjustment of operating criteria. The current strength is adjustable from 10 to 220 A. The model has the function of hot start and arc forcing.

Welding machine ELITECH AIS 220 Prof (TIG, MMA)

Advantages:

• hot start
• anti-stick
• arc forcing
• setting accuracy

Flaws:

• not detected

Aluminum electrode welding

The abbreviation MMA stands for manual arc welding using coated electrodes. The method is used to connect structures and parts made of aluminum that do not bear a critical load. This is due to the disadvantages of MMA welding:

• it is difficult to get an even seam;
• the process of melting the electrode is accompanied by strong splashing;
• low strength of the created seam, characterized by a porous structure;
• It is difficult to clean the seam from slag.

MMA welding can be used if the metal has a thickness no less than the same characteristics of the electrode. The method is used when it is impossible to use expensive and bulky equipment.

Inverter welding

Welding aluminum with an electrode is a complex operation. To facilitate the process, it is recommended to use an inverter, which has a number of advantages:

• efficient consumption of electrical energy thanks to a converter that automatically turns off when it stops working;
• 95 percent efficiency, achieved due to the presence of a pulse-type semiconductor high-frequency converter that prevents the appearance of inductive losses;
• stable burning of the arc, which ignites as quickly as possible after the electrode strikes the metal;
• the regulator knob allows you to accurately set the desired value of the welding current, depending on the thickness of the electrodes used;
• delivery of the required voltage even during power outages due to automatic adjustment of the pulse-type converter to the input parameters.

An inverter machine for aluminum welding is compact, lightweight equipment. This allows you to conveniently carry and transport the device when performing work.

Technological features of welding

First, aluminum electrodes are selected for inverter welding. They are characterized by a high melting rate. For this reason, the welding process is 2-3 times faster compared to other materials. All coated consumables used in aluminum welding are suitable for investors. The most commonly used rods are the brands OZANA, UANA, OZA and the OK series from the Swedish company ESAB. To form a reliable welding seam, all electrodes must be preheated. A special stove is used for this.

Before welding aluminum with an inverter and when using other technologies, the metal is cleaned of dirt and oxide film using a brush with stiff bristles and any available detergents. After this, you need to rinse the surfaces with cold water. Then the metal is degreased with acetone, white spirit or other organic solvent. For small aluminum parts, the elements are immersed for several minutes in an alkaline solution with a temperature of no more than 60°C. Then the surfaces are sanded with a brush with metal bristles. It is not allowed to use abrasive agents because the working particles remain on the metal. Finally, the surfaces are washed using a solvent, which must dry on its own. Preparation allows you to get a non-crooked and durable seam.

Manual arc welding of aluminum is performed with a current of reverse polarity, the direction and magnitude of which does not change. It is used due to the formation of an oxide film on the surface of the metal. It is destroyed due to cathode sputtering precisely with reverse polarity. The current strength is calculated based on the following relationship: for every 1 mm of electrode thickness, from 20 to 25 A is required.

The surfaces of aluminum parts must be heated to 400°C to create a high-quality seam. Heating eliminates the possibility of metal deformation and the formation of hot cracks.

When welding inverter aluminum, the electrode must be in a vertical position. It is also possible to hold the rod at a slight angle. When working, it must be moved in the direction of the seam. Experienced welders advise not to make transverse movements, but to perform the process on a short arc exclusively in one pass.

It is imperative to remove the slag crust from the end of the electrode and the crater between the parts being connected if the arc breaks. This will make it easier to re-ignite the arc and continue welding. It is recommended to try to cook continuously using one electrode until the consumable is completely melted. After creating the seam, the area must be cleaned of slag and washed with water.

Popular machines for aluminum electrode welding

1) Resanta SAI 190PN
The design of the device is based on advanced inverter technologies based on a rectifier with pulse-modular regulation and a current stabilizer. The device is powered by a conventional single-phase 220 V power supply. This inverter welding machine has become a fairly common tool for creating the strongest possible connection of metal parts in private households, workshops and other professional or domestic situations. Using this fairly compact device, you can ensure high quality and accuracy of the weld formed by an electrode using direct current. The delivery set includes a cable with a special convenient electrode holder, as well as a cable with a fastening device that ensures the circuit is closed. The length of each cable is 2 meters.

Peculiarities :

• overheat protection
• ANTI STICK function
• “HOT START” function (hot start)
• ARC FORCE function
• Voltages from 140 to 240 V
• Welding current 10-190 A

Welding inverter Resanta SAI-190PN

2) Kittory KT 220 Prof

Inverter welding machine for professional use. Designed for arc welding with coated stick electrodes (MMA technology). The instrument panel is equipped with an electronic ammeter. Improved design - plastic pads, handles and shoulder straps. The KT 220 Prof inverter is equipped with a stabilization unit. Operates reliably from a mains voltage of 140 V. Welding using TIG technology is provided. Insulation class H. Electromagnetic compatibility class A. Protection degree IP21S. The cooling system is forced (fan).

Peculiarities :

• overheat protection
• ANTI STICK function
• “HOT START” function (hot start)
• ARC FORCE function
• Voltages from 140 to 220 V
• Welding current 20-220 A
• PV 80%, efficiency 85%

Welding inverter Kittory KT 220 Prof

3) Foxweld Master 202M

Master 202M is an inverter-type welding machine, manufactured using modern IGBT technology, designed for manual arc welding with a coated piece electrode using direct current. The device is characterized by increased reliability, high power, good technical characteristics, has software-installed Hot Start, Antisticking characteristics and an adjustable Arc Force function, and operates at reduced mains voltage (from 140V).

Peculiarities :

• IGBT assembly technology
• Very simple and convenient control panel
• Digital display to show the welding current value
• Built-in Hot Start, Antisticking and Adjustable Arc Force
• 2 LEDs for monitoring the operation of the welding source
• Light weight

Welding inverter Foxweld Master 202M

Svarog PRO TIG 200 P DSP AC/DC (E201) (TIG, MMA)

​Photo: https://beru.ru

The compact welding machine PRO TIG 200 P DSP AC/DC (E201) from Svarog, built using SMT technology with tunnel airflow, allows you to perform professional TIG welding with both direct and alternating current. At the same time, the user has access to the TIG Pulse pulse welding mode, TIG spot welding, 2T/4T modes and manual MMA arc welding. Modern functions of the svarog e201 allow you to achieve stable ignition and burning of the arc over the entire wide range of welding current. The device meets the highest safety and reliability requirements thanks to its IP21S protection class, improved cooling system and built-in overheating protection.

Welding machine Svarog PRO TIG 200 P DSP AC/​DC (E201) (TIG, MMA)

Advantages:

• two types of welding
• multifunctionality
• pulse and spot mode
• comfortable handle

Flaws:

• heavy
• high price

How to choose aluminum welding equipment

When choosing welding equipment, you first need to make sure that it is appropriate to purchase it.
High-quality devices are not cheap. If you rarely use them, then the point of such a purchase is not justified. However, if you need to purchase a welding device, you should pay attention to the points indicated in the descriptions for each type.

The main principles are:

• Ability to regulate and switch current modes: from the lowest settings to the highest (the maximum permissible power should be at least 250 A).
• The main thing for a conventional inverter for manual arc welding is the presence of a function for changing polarity and switching the device to direct current.
• Welding machines with the specified TIG function must be able to connect a torch with argon supply. It's minimum. But it is desirable that it have settings for gas supply and various modes.
• Semi-automatic machines, in addition to all the specified capabilities, must regulate the wire feed.
• For all types of devices, it is important who made it. There are a lot of cheap Chinese manufacturers who do not have licenses to produce products. The leading brands of such equipment were and remain ESAB, KAISER, TESLA, RESANTA and others.

Without experience, it is best to contact an experienced welder before purchasing, who will help you select the required equipment for you and point out the necessary functions.

If you have experience in choosing, purchasing and using a welding machine for welding aluminum, share it in the discussion block of this article.

Wester MINI 220T (MMA)

​Photo: https://beru.ru

Wester's MINI 220T (MMA) is considered the smallest and easiest-to-use inverter for aluminum welding. The power ratings of the device range from 30 to 220 A, and there is also decent power - 7 kW. The device is capable of working for a long time without stopping under significant loads and voltage sags. The front panel has a liquid crystal display, sensors for connecting to the power grid, and overload. There are functions of smooth adjustment, hot start, anti-stick, built-in thermal protection. The ventilation grilles are protected from scale. If you don’t yet know which welding machine is better, then take a look at this model.

Welding machine Wester MINI 220T (MMA)

Advantages:

• ease of control
• long continuous work
• resistance to loads and current surges
• built-in thermal protection

Flaws:

• no transport handle

This concludes our article about welding machines for welding aluminum. Happy shopping and making the right choice!

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Installation regulators

Aluminum requires fine adjustments and lowering the current during the welding process. The main functions that an aluminum welding machine should have:

• contactless ignition;
• zoolocation – adjusting the arc polarity ratio;
• AC balance adjustment.

Non-contact ignition ensures the ignition of the arc without striking the part and its constant burning.

When operating in AC mode, the polarity of the arc changes from direct to reverse and vice versa. Zoolocation allows you to select the optimal direction of the current and the frequency of polarity changes.

The duration of pauses and pulses is adjusted by a balancer depending on the thickness of the metal being welded.

Additionally, the welder sets:

• starting current;
• magnitude and nature of the main current;
• Arc forcing.

In addition to these functions, several timers ensure high-quality welding. They are responsible for:

• gas supply before welding;
• current decay time;
• supply of gas after completion of work.

shielding gas is supplied before the start of the welding process - ignition of the arc. This ensures that the bath is completely closed before the melting process begins.

You need to start welding aluminum at a high current, then lower it. The timer automatically reduces the current after a certain time after starting operation.

Aluminum cools quickly, but it still takes time to prevent the seam from oxidizing and cracking. After the electric arc is turned off, gas is supplied to the working area for another 5–7 seconds .

Recommendations for selection

Inverter welding machines for aluminum welding are specialized equipment. Therefore, in order to rationally invest money in a purchase, it is advisable to take into account the following factors:

• Proposed types of work and processed material. The most versatile unit is one that combines argon arc welding with manual electric arc welding using all types of single electrodes.
• The maximum current strength (respectively, power) will expand the functionality of the device.
• To perform field work, it is advisable to take into account the weight of the assembled unit and ease of transportation.
• The price of welding equipment will pay off with intensive use, that is, when building your own home or for a small business (part-time work as a welder).

When choosing, you need to pay attention not only to the cost of the equipment, but also to the richness of options and additional equipment.

We ask readers who have experience working with inverter-type welding equipment using argon to share their knowledge in the “comments” section. This is a must for novice welders. However, experienced craftsmen will also learn something useful for themselves.

Welding modes

The peculiarities of the technical properties of the metal caused the emergence of special welding technologies at one time:

• MMA is a mode of manual electric arc welding with a stainless electrode.
• MIG/MAG - welding on a semi-automatic machine using inert gas as protection.
• TIG is the joining of metals with a tungsten non-consumable electrode in a cloud of protective gas and without it.

Separate modes can be applied for each metal. For example, stainless steel is connected in MMA mode using an electrode made of the appropriate material. But this does not apply to aluminum. In addition, steel is welded using direct current of reverse polarity, which is also not suitable for light metal.

Process Features

Difficulties in welding are explained by the properties of metals:

1. Stainless steel. The presence of alloying additives (up to 20%) gives the material negative properties (for the welding process):

• Reduced thermal conductivity (up to 2 times) compared to conventional steels. This can cause local overheating, leading to the destruction of intercrystalline bonds.
• Increase in linear expansion coefficient. The consequence is shrinkage of the metal, the appearance of deformations up to cracking.
• Increased electrical resistance. The result is heating of the electrode and melting before the end of the operation.

1. Aluminum and alloys. Features of connection technology:

• Thermal conductivity. When connecting thick parts, some of the heat will be intensively dissipated deep into the product. The seam will become loose and fragile.
• The difference in the melting temperatures of the protective film (2100°C) and metal (660°C). At low constant currents the process is almost impossible to implement.
• Chemical activity. Aluminum reacts actively with oxygen in the air, so the welding area must be isolated.

The destruction of the film is facilitated by the choice of working on alternating current (stainless steel - on direct current).

Basic equipment parameters

The choice of welding equipment is determined by the main technical characteristics:

• Number of operating modes (MMA, MIG/MAG, TIG). The longer the list, the more versatile the device.
• Welding current strength. Determines the thickness of the workpiece being processed and the diameter of the electrode used (for MMA mode).
• The input network voltage is 220V or 380V (single-phase or three-phase, respectively).
• Weight of the assembled unit.
• Total cost including additional equipment (gas kit).

Model Brima TIG-200P

A device for working in a cloud of protective gases using a refractory tungsten electrode. Two modes are installed: MMA and TIG. They produce compounds of aluminum and its alloys, black, alloy and stainless steels

Characteristics:

Brand - Germany. Manufacturer: China.

Model Svarog TIG200 AC/DC DSP TECH 104

The unit belongs to the professional class.
Two modes are used: MMA and TIG. Ensures stability of the welding process when the mains voltage drops to 160-170V. Has a high efficiency of 85%. Characteristics:

Brand - Russia. Manufacturer: Russia.

Model Cedar TIG200P AC/DC 220V

The welding machine is used for working with ferrous and alloy steels, non-ferrous metals, including aluminum. Convenient when working with an unstable electrical network, for example, in rural areas. Belongs to the professional series.

Characteristics:

Brand - Russia. Manufacturer: China.

Model Elitech TIG AIS 200AD AC/DC

An inverter for welding aluminum is used in auto repair shops, construction, and when installing metal structures. Connects aluminum, titanium, magnesium and its alloys, various steels. There are two operating modes: manual arc and argon arc welding. The device produces alternating and direct current.

Characteristics:

Brand - Russia. Manufacturer: China.

Model Aurora PRO Overman 160 Mosfet

Semiautomatic inverter type. Provides reliable welding of aluminum and its alloys. The unit belongs to the industrial class. It is used for domestic purposes and for industry. Allows you to configure welding current parameters over a wide range. The wire feed speed is 2-15 m/min.

Characteristics:

Brand - Russia. Manufactured in China.