What amperage range to use during TIG Welding Aluminum?

One important rule for choosing proper amperage for TIG Welding Aluminum is to use 1 ampere for every thousandth (1/1000) of the aluminum thickness.

For example, to TIG weld an aluminum piece that is 1/8 inch in thickness would require 125 amperes.

However, as the thickness of the base material is higher, the above rule is no longer correct.

If you weld a 3/8 inch piece of aluminum, you only need a power source of 280 amperes (not 375 amperes, as per the rule).

Also, the amperage also depends on the type of joints.

For example, a T-joint would demand a higher power source than a Butt joint, because:

• In T-joint, heat can flow in three directions,
• While in the Butt joint, heat flows in two directions only.

To set the desired amperage, you can:

• Make use of a foot pedal or fingertip
• Rely on your TIG Welder by changing AC Balance (increasing EN), or setting AC amperage independently (if allowed by the machines).

Below is an Amperage Chart for your reference