best Welder for Aluminum (2020 Reviews)

If you are looking to do aluminum welding, you don’t just need any welder that comes your way. That’s because aluminum is a composition of complex chemical and physical ingredients, so you’ll need a welder that’s verily engineered for aluminum if you want to get desired results.

Truth is, not every welder will do well with aluminum metals because of its inherent nature. That’s why you need to do your homework well if you don’t want to be frustrated.

The best welder for aluminum will let you weld aluminum as well as other materials when needed. If you are contemplating to do aluminum welding, these welders will help you get the work done satisfactorily whether you’re a professional or new welder.

best Welder for Aluminum (Reviews)

1. Everlast PowerTIG Welder

The Everlast Power Equipment is the company behind the production of Everlast PowerTIG Welder amongst other powerful reliable welders.

It has a power voltage output of 120 and 240 volts which is sufficient enough to produce excellent welds on almost anything.

It is designed to weld aluminum materials of varying thickness without an issue as well as relevance repairs and maintenance on your garage and farm projects.

The arc force control boosts arc performance while minimizing on spatter to improve your welding experience. Arc control is stable to help you do both stick and TIG welding.

This unit is truly portable weighing very light to move anywhere with ease. You can even use the welder with almost any generator with a voltage output of 120V (3500 watts) as long as it is certified as clean power by a credible manufacturer.

For beginner welders, this welder is simple to use plus, it is well put together within a short duration. This welder is top quality too.


  • Has a foot pedal
  • Arc is smooth and stable


  • Expensive

2. LOTOS 140 Amp MIG Welder

What you’ll love most about this welder is the incredibly stable aluminum wire feeder that leads to an amazingly user experience. The aluminum wire feeder is top quality to withstand frequent use on a daily basis.

Aside from using the welder on aluminum, it also works well on mild steel, stainless steel and lots of other metal types. Plus, you can use this unit with industrial standard wire spools that are 4 or 8 in.

For new welders, the LOTOS 140 connects to a 110V household sock and is simple to set up in not more than 10-minutes. There’s even a thermal protection that prevents the system from heating up after a long use.

We love the digital displays that lets the user to precisely adjust both the welding voltage and the wire feed speed at a glance if you want to do repeatable welding. The ground connector cable will make the work easy for you when you are adjusting the wire feed speed and voltage.

Even better, you don’t need to use shielding gas if you’re using flux core wire which is a plus if you want to use the welder away. It is easy to use, producing nice welds with flux wire. Great for random fixing of stuff on materials with little power demand.



  • No need of shielding gas
  • Portable
  • Digital displays


  • Requires gas when using solid wire

3. LOTOS TIG200ACDC Aluminum TIG Welder

The LOTOS TIG200ACDC is a dual voltage welder designed to work either on a 110V or 220V home output socket. Arc is easy to start and easy to get stable with the adjustable striking arc.

It can handle a range of welding tasks such as aluminum welding, mild steel as well as stainless steel. Meaning it can handle thick metals as well as thin materials producing nice and solid welds on any metal. To weld aluminum, this unit encompass a square-wave inverter that lets you do accurate welding on fine aluminum materials.

It doesn’t matter if you want to do stick or TIG welding, you can use the unit pretty easily with 100 percent superior performance. It even comes with a foot pedal to let you operate the machine efficiently.

Setting up the unit is straightforward with minimal adjustments for new welders. The regulator and all the other accessories are top quality as well.

Controlling the machine is simple for novice welders as the package includes a well-crafted user-friendly manual with easy tips on how to put together the pieces. It is also compact and super simple to move around.


  • Easy to get the arc stable
  • Dual voltage output
  • Square-wave inverter for accurate aluminum welding


  • Mask not great

4. Hobart 500559 Handler

The Hobart 500559 Handler works well on a 115V socket output, meaning the unit is designed for small stuffs that do not require a lot of power as well as heavy projects.

Because it is strong, this welder can weld a range of metals from cast iron, copper, flux-cored aluminum titanium, brass, magnesium as well as other types of metal materials. It can handle 24 ga. to not less than 1/4 “of mild steel.

It is versatile, suitable for simple repairs such as household repairs, autobody repairs as well as heavy projects. Its duty cycle is 20 percent at 90 amps.

You’ll be impressed by the 5-position control settings that lets you adjust the voltage on different material thickness. It improves the welding experience by stabilizing the arc performance.

The unit is engineered to last with an all metal drive. Setting up is simple within a couple of minutes; and controlling the machine is also simple even by first time welders. Weighing as little as 57 lbs, this unit is truly portable for outdoor welding.


  • 5-position voltage control settings
  • Weighs light
  • Simple to set up


  • We wish the unit was made with dual voltage output

5. Weldpro Welding Machine

The Weldpro Welding Machine goes beyond doing the ordinally welding on aluminum and steel as this unit will work pretty well on other materials as well.

With a 200-amp trigger switch, this welder works incredibly well with a DC and AC control to help you do stick or TIG welding. The arc is smooth and stable producing welds that are solid.

We love the sturdy foot pedal as well as the argon regulator that improves the user’s performance. The fans start off as soon as the machine is started to prevent the unit from heating up.

You’ll like the long duty cycle of 60 % that lets you weld for long in demanding moments as well as the LEDs that displays the settings allowing you to weld on varying materials.

It’s a fantastic welder for the money, ideal for professional as well as new users. For new welders, the package comes with everything to get you started right from the box. It is lightweight to transport away from home wherever you need.


  • Adjustable pedal amperage knob
  • Long duty cycle


  • Unit not cheap

Features to Consider When Looking for Aluminum Welder

Power Amperage

Welding aluminum will definitely require more power than when you’re welding other materials like stainless steel or mild steel.

A great welder for aluminum should have a minimum of 200 amp to give you flexibility to weld aluminum metals from as thick as 31mm to as high as 47mm.

The higher the amperes range or limit the greater the machine is to weld on unlimited thickness. For example, a unit with 230 amp can weld aluminum materials which are as thick as 60mm.

Duty Cycle

The duty cycle is the estimation of how long you can operate a welder non-stop in a record time of 10-minutes. The longer the duty cycle the better the machine.

For example, if a welding machine encompass an output of 70 amp and duty cycle of 10 percent, it means the unit is supposed to run for one minute then allow the machine to rest for a span of 10 minutes before proceeding.

Using the machine beyond its duty cycle will prompt the system to overheat. So, as you can see, a longer duty cycle is the most practical if you’re running a commercial welding business or using the welder on a daily basis.

Lightweight Welder

A light welder doesn’t mean the unit is not great. If you’re looking to do a lot of outdoor welding, a light in weight welder will honestly be a great option.

Transporting a cumbersome welder every often could be wearisome, so it’s important you check the manufacturers label to see how the product weighs.

Stick Welder Vs TIG Welder Vs MIG Welder

A stick welder creates an electric arc between connecting metals and the stick. You can find this machine in either DC, AC which is best for aluminum welding or a combination of AC/DC. It is the most appropriate for home use to weld farm projects such as rusty metals, joints as well as alloys.

TIG welder utilizes tungsten inert gas to melt the metal that need to be joined. It is a complicated technique for first-time welders who may take a while before getting a hung of it. However, this machine is great in a myriad of metals that range from aluminum, alloys, steel, magnesium and much more.

MIG welders on the other hand are user friendly for new as well as expert welders. With MIG welders, you can either connect wire to the electrode current or use a shielding gas to connect together metal pieces of aluminum, mild steel as well as aluminum. They’re simple to use and very affordable if you’re looking for a simple unit for home use.


Welding machines are available n AC, DC or a combination of both AC and DC. If you are looking to perform welding with various metals, it’s prudent you look for a welder with both options. However, an AC welder is a great option if are anticipating to do only aluminum welding.

Final Thoughts

If you’re a seasoned welder, we’re sure you’re aware that welding aluminum is not the same as welding other metals. The process maybe the same, but you’ll need a totally great welder when working with thin materials such as on aluminum projects.

Unfortunately, choosing between the different brands may be overwhelming especially when you’re not sure whether to choose a Stick, MIG or TIG welder. Or how to choose and narrow down to the best welder. With this guide, identifying the best welder for aluminum should be pretty simple.

error: Content is protected !!
Scroll to Top