Weld Creations provides aluminum welding and fabrication for manufacturers across Los Angeles and Southern California. We TIG weld aluminum on AC, choose filler for the alloy and the finish, and control the oxide, porosity and distortion problems that make aluminum one of the most demanding everyday metals to weld well. The work ranges from enclosures, frames and brackets to aerospace components and production runs.
Why aluminum is demanding
Aluminum welds are easy to make and hard to make right. Four properties drive every decision:
- The oxide layer. Aluminum is covered by aluminum oxide, which melts around 3,700°F while the metal melts near 1,200°F. The oxide must be removed before welding and broken up during welding, which is why aluminum is TIG welded on AC.
- High thermal conductivity. Heat moves away from the joint quickly, so aluminum needs more heat input at the start of a weld and careful control as the part warms up.
- Porosity. Hydrogen from moisture, oils and hydrated oxide causes gas porosity. Cleanliness and dry materials prevent it.
- Heat-affected strength loss. Heat-treated alloys lose strength next to the weld, which has to be designed for.
How we weld aluminum
Cleaning. Joints are degreased with solvent, then the oxide is removed with a stainless wire brush or carbide tooling reserved for aluminum only, immediately before welding. Filler wire is kept clean and dry.
AC TIG with balance control. Adjusting AC balance and frequency lets us tune the cleaning action and the penetration for the joint, which gives narrow, controlled welds on thin sheet and full fusion on heavier sections.
Preheat where needed. Thick sections may be preheated moderately to establish a weld pool without excessive heat input. Heat-treated alloys have preheat limits so the base metal isn’t overaged.
Distortion control. Aluminum’s high thermal expansion moves parts. Fixturing, tack sequence and balanced welding keep geometry in tolerance.
Alloys and filler selection
| Base alloy | Heat treatable? | Common filler | Notes |
|---|---|---|---|
| 5052, 5083, 5086 | No | 5356 | Good weldability; strong as-welded; marine and enclosures |
| 6061, 6063 | Yes | 4043 or 5356 | HAZ strength loss; 5356 for anodize color match and strength |
| 3003 | No | 4043 or 1100 | Formable sheet; tanks and ducting |
| 2219 | Yes | 2319 | Weldable aerospace alloy |
| 7075 | Yes | Not recommended | Prone to hot cracking; discuss alternatives |
4043 or 5356? 5356 gives higher strength and a better color match after anodizing. 4043 flows well and resists solidification cracking on 6xxx alloys, but anodizes to a dark gray. Magnesium-rich 5xxx alloys are welded with 5xxx filler. We choose the filler with you based on the alloy, strength requirements and finish.
Designing welded aluminum parts
- Plan for the weld zone. In 6061-T6, the heat-affected zone has significantly lower strength than the base metal. Size members for as-welded strength, or specify post-weld heat treatment.
- Tell us about anodizing early. Filler choice, weld prep and blending affect the final appearance.
- Keep joints accessible. Aluminum rewards good torch access and consistent travel.
- Avoid 7075 for welded structures. Use a weldable alloy, or design a mechanical joint.
What we build in aluminum
- Enclosures, housings and electronics chassis
- Frames, stands, carts and platforms
- Brackets and mounts, including machined-and-welded components
- Aerospace tooling, fixtures, ground support equipment and components
- Food equipment frames and guards. See food and beverage fabrication.
- Custom fabrications and production runs
How we check aluminum welds
Every aluminum weld is visually inspected for complete fusion, consistent bead profile, undercut and surface porosity. Where your drawing calls for it, we arrange penetrant or radiographic inspection through our partner network, check critical dimensions after welding, and document results with photos. For production parts, the first article is approved before the run begins, so every part matches.
Material sourcing and certifications
We can source aluminum sheet, plate, extrusions and tube in the alloy and temper your drawing calls for, with material certifications, or weld material you supply. Tell us the temper you need after welding, so heat treatment can be planned if required.
Why Weld Creations
Aluminum is one of the metals where a welder’s skill shows most, and precision TIG welding is our core process. We’re AWS D17.1 certified, which covers aluminum alloys. Machining, anodizing, powder coating and heat treatment are available through our partner network, so you receive finished parts. See our capabilities.
Request an aluminum welding quote
Send the drawing, alloy and temper, thickness, quantity, finish (anodize, powder coat or raw), and your timeline. We reply within one business day.