Tig Welding Aluminum Without High Frequency: Method & Tips

Tig Welding Aluminum Without High Frequency

Many people may be hesitant about tig welding in aluminum without high frequency whether it is a good alternative at all. You can apply a low frequency or DC power supply as a low-cost tig welding alternative for aluminum. But, there are some limitations. 

However, there are many things you need to know about aluminum tig welding without high frequency. You should also know how tig welding works without high frequency although it depends on the condition of the metal.

This article will discuss details of aluminum tig welding without high-frequency, and you will be aware of various information related to this. Moreover, there are answers to your unknown questions.

6 Easy Steps Of Tig Welding Aluminum Without High Frequency: Best Way

There are some simple steps of aluminum tig welding with low-frequency. You may fail to do this due to a lack of proper procedure. Follow the steps below:

Step-1: Gather Necessary Equipment

Tig welding in aluminum requires a primary preparation that will help you do your job perfectly. You need a few essentials to put together as part of the preparation:

  • Wire brushes;
  • Welder;
  • Hand gloves;
  • Safety glasses;
  • Automatic darkening welding helmet;
  • Table.

Step-2: Prepare The Table

After assembling the necessary tools, your first task is to prepare the welding table where you want to weld the tig. Metal tables should usually be used for welding, but you can also use wooden tables according to your wish.

From the top of your welding table, remove the unnecessary things of the moment that may interfere with your work as it is a delicate task. Once the table is ready, start using the welding machine, aluminum, and wire brushes.

Step-3: Clean The Surface

Now remove dirt and oils from the surface of aluminum, or they may get stuck during welding. Wire brushes are very effective in this regard because they remove dirt and oil by pushing hard. Remember you should not use any brush for this purpose.

Separate brushes are rated for aluminum, so you can never remove aluminum dirt with a brush used in stainless steel. Moreover, it can cause stains on the aluminum.

Step-4: Prepare The Machine

At this stage, you need to set up your welding machine and get it ready for work. Also, you have to decide which power supply system you want to work with. You can use either AC or DC. If thin aluminum welding is required, low-cost non-high frequency DC is recommended.

It will be difficult to work without high frequency in the case of welding thick aluminum. Moreover, it also extends the duration of welding. So choose the current considering the thickness of your metal.

Step-5: Take Safety Precautions

Safety equipment must be worn before starting welding aluminum. Sparks are scattered during welding, so it is crucial to wear hand gloves to protect them from direct touch. Also, the most vital thing you need to wear is an auto-darkening welding helmet.

Tig welding is a delicate job, and you have to be very close to it while welding aluminum. As a result, the eye position is much closer to the spark. This intense light of welding is harmful to the eyes. An auto-darkening helmet protects your eyes from the sparks.

Step-6: Start Welding

It is time to start welding after taking the necessary safety measures. When you weld aluminum, it needs to move the electrode towards the rod. Place the rod next to the electrode on the side where the weld will be made. Now weld the aluminum parts that need to be welded a little near the two ends to stick it properly.

Now weld the whole line periodically so that there is no gap anywhere. If your metal is thin, you can complete the welding without high frequency. However, in the case of thick metal, high frequency is required.

7 Useful Tips For Tig Welding Aluminum Without High Frequency:

Some tips you should remember when welding aluminum without high frequency. So, know the mentioned tips below:

Tip-1: Aluminum tig welding requires a high-frequency setup where newcomers often make a mistake. In some cases, it is possible to work without a high frequency that they do not know.

Tip-2: Many people make mistakes in choosing the size of the rod. In most cases, newcomers work with a small filler rod so that it melts before the welding is complete.

Tip-3: It is recommended to use a stainless steel brush for aluminum. In this case, using a carbon steel brush is a great mistake.

Tip-4: Newbies usually use high torching to melt the filler metal so quickly. That is why you should not do too much torching in the corners.

Tip-5: Never use pure tungsten as it is tempting but lacks efficiency. With or without high frequency, it can work well.

Tip-6: Some welders sometimes force electrodes which should not be done all at once. Note that the larger the electrode force, the less effective it will be.

Tip-7: Be sure to take safety precautions. In welding, you will need to wear safety equipment in every case if you use high or low frequency.

Difference Between Tig Welding Aluminum With And Without High Frequency:

You may want to know the differences between high frequency and low frequency in the case of tig welding aluminum. Well, below are the significant differences between them:

DifferencesWithout High Frequency(DC)With High-Frequency (AC)
SmoothnessNot smooth like high frequencyBest welding output 
HandlingEasy to handle Difficult compared to DC
SprinklingLess spatterMore spatter
Blow fixingIncapable to fix arc blow issuesFixes the arc blow problems 
CostLower costHigh cost than low-frequency
ReliabilityMore reliable than high-frequencyLess reliable

Related Questions About Tig Welding Aluminum Without High Frequency:

Is High Frequency Required For TIG Weld Aluminum?

There is no doubt that tig welding can be done in aluminum without high frequency. But, high frequency is recommended in most cases. The high frequency or AC power plays the most-effective role for better welding. Moreover, it also solves arc blow problems.

For tig welding in aluminum, the frequency is set from 120 to 200 Hz which is considered standard. High-frequency welding makes the pressure harder and much better so that it can easily penetrate deep and more precisely.

Why High-Frequency Is Recommended To Tig Welding Aluminum?

Aluminum tig allows for high-quality best welding for aluminum. Aluminum tig welding has several advantages over DC power supply. The welding requires a high frequency to penetrate deep, which allows fine welding under pressure. Its hot electrode never mixes with the original material, so you can quickly re-ignite. Although this is a somewhat expensive method, it is still quite effective compared to low frequency.

How Does Frequency Affect TIG Welding Aluminum?

Frequency reacts specifically to aluminum tig welding. In many cases, beginners do not understand the difference, but they think that low frequency and easy to handle aluminum tig welding at low frequency will give better results. High frequency works perfectly in narrow spaces.

It is much easier to weld using high frequency at different angles, including fillet welds, laps, root passes, and joints. Although the low frequency is acceptable in some cases, you need to know when to use it.

How Does High-Frequency TIG Welding Work On Aluminum?

During tig welding in aluminum, high-frequency electrical power is converted into thermal energy. It helps the metal to melt. When you weld a thick aluminum tig, the electrical power must be such that it creates high pressure. Because it is not possible to weld thick aluminum without pressure.

Allows proper application of high-frequency aluminum to the welding area. It may be tough to handle aluminum tig welding in high frequency if you are not experienced in the process. In this case, the advice is to work on DC power first, then practice high frequency.

Can You TIG Welding Aluminum Without High Frequency?

As an affordable alternative to high frequency, you can weld tig in aluminum without DC power. However, with a DC power supply, this work is quite time-consuming. It is easy to handle, and it is possible to get much better output if you work in the proper steps.

Sometimes it can be complicated to get to the puddles because the machine does not have as much power as high frequency. So, if you are a beginner and want to learn how to tig welding aluminum at a low cost, then a DC power supply is a better alternative.

Which Type Of Aluminum TIG Can Be Welded Without High Frequency?

You can use low-frequency aluminum things that are thinner, and also, where deep welding is not required. Although the low frequency is used in thin aluminum, it is effective quickly. On the other hand, high frequency is always recommended for thick aluminum.

It applies pressure to the metal, making deep welding very easy. Although it is recommended to use high frequency for aluminum tig welding, you can go for less expensive alternative DC power occasionally.

Final Words

Aluminum tig welding can use either high frequency or low frequency, but you need to know the difference in their usage. There are some advantages to high-frequency welding with some difficulties. It makes more spatter that is very low in the case of DC or low frequency.

Moreover, considering the cost and simplicity, many people do aluminum tig welding without high frequency. Hopefully, the above discussion and difference table in this article will make your idea clearer.

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Kaosar Ahmed

This is Kaosar Ahmed. I’m the main publisher of this blog. Welding Leader is a blog where I share welding tips and tricks, reviews, and guides. Stay tuned to get more helpful articles!

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