Aluminium welding is a different discipline from steel welding. The material conducts heat rapidly, has no colour change as it approaches melting point, and forms an oxide layer that melts at a much higher temperature than the base metal. Both MIG and TIG processes are used for aluminium fabrication, and the choice between them depends on the component geometry, the required weld quality, and the production volume.
When TIG is the right choice ¶
TIG welding (GTAW) on aluminium uses AC current to break up the oxide layer while the arc melts the base metal. It gives the welder precise control over heat input and filler addition, which makes it the preferred process for thin-wall sections, complex joint geometries, and applications where weld appearance matters. Handrails, architectural panels, and food-grade enclosures. The process is slower than MIG, which affects cost on larger components.
When MIG is more appropriate ¶
MIG welding (GMAW) on aluminium uses a push-pull wire feed system to handle the soft aluminium wire without birdnesting. It deposits metal faster than TIG and is more economical for thicker sections and longer weld runs. Equipment skid frames, transport boxes, and structural members. The weld profile is wider and less refined than TIG, which is acceptable for most structural applications but less suitable where a smooth, flush finish is required.
Alloy selection and filler metal matching ¶
The most common aluminium alloys in Japanese industrial fabrication are 5052 (good corrosion resistance, used for enclosures and marine applications) and 6061 (higher strength, used for structural members and transport equipment). Filler metal selection depends on the base alloy and the service conditions. For 5052, ER5356 filler is standard. For 6061, ER4043 is commonly used, though ER5356 is preferred where the weld will be anodised. We confirm filler metal selection with the client before welding starts.
For aluminium fabrication enquiries, send us the alloy specification, the required finish, and a drawing or sketch. We will confirm the process and filler metal selection in the quote.