How to TIG weld aluminum beverage cans together

I show how to weld aluminum cans together with a cheap import TIG welder. I am not a professional welder, so some of my advice may be unconventional or even wrong, but these methods work well for me. With a 3/32" electrode and large gas lens, I don't have to change the torch setup for nearly any kind of common welding. Let me know if you have any questions or would like me to make more welding videos.

Some things that I have learned:

Don't use pure tungsten electrodes. The new rare-earth blends work very well on nearly all metals.

Sharpen the electrode to a very fine point for low-current welding, and sharpen it like a pencil for higher (eg over 100A) welding.

Keep the electrode balance control electrode negative ("weld") and only shift toward electrode positive ("clean") when absolutely necessary.

The welder's pulse feature turned out to be not as useful as I originally thought. It just seems to complicate things. It's definitely possible to make great welds without it.

Use fat electrodes. Some people claim that using an electrode that is "too large" for the weld current will cause the arc to wander. Nope. Just grind it to a sharp point. Thin electrodes 1/16" and .040" overheat much too easily, and provide no apparent benefit. .040" electrodes are very frustrating.

Use thin filler rod. It's much easier to feed thin rod quickly than feed fat rod slowly. As I mentioned in the video, it's easier to sneak a thin filler rod into the puddle while keeping the torch close to the surface.

Category:

Science & Technology

Tags:

• howto
• how
• to
• TIG
• weld
• aluminum
• cans
• Tungsten
• Inert
• Gas
• welding
• AC

[helicrashpro]

I have heard those machines suck. Not sure how cheap they are but does not seam like they are worth the cost savings. If you are wanting a cheap tig welder I have heard (have not used one myself) that the everlast welders are pretty decent.

[bkraz333]

@helicrashpro This is an "Everlast" welder. Check google images. The yellow paint indicates their older model. I wouldn't say it sucks, since it does weld quite well, but yeah build quality is typical of cheap import tools.

[KiloSierraAlpha]

Ben, have you tried welding titanium? Is it the same thing as Al?

[bkraz333]

@KiloSierraAlpha Titanium is more reactive than aluminum and requires very good shield gas coverage. I believe most titanium is welded inside a "glove box" or similar chamber that allows the parts to be completely surrounded by argon. I've never tried it, but the best approach for hobbyists would be to buy a cheap sandblasting cabinet, and seal it up, then fill with argon.

[RatkoUSA]

The best explanation of TIG I've seen yet.

[bman20000]

@KiloSierraAlpha just did my first titanium test the other day. Id say its more similar to stainless than aluminum. meaning you need to be very aware of heat control, and BK is right it is more reactive, you have to make sure the coverage on both sides of the weld(on thin stuff) has enough gas coverage. I did my test with just back purging, no case. The rod gets sticky fyi so you kinda have to be a bit more accurate and diliberate with where its going.

[honeybunchickens]

good job on the welding

[IcEcOlDkIlLa0601]

Welding Al needs AC current, which has its own cleaning action. I weld with my schools TIG welders and I have never preped the Al before welding since you can set the balance farely well.

[bigdaddy63978]

not to bad..



[landlockedviking]

very well done , thanks!



[2WildRazn]

@bkraz333 no it doesnt have to be in a glove box 

[jwwelder07]

I noticed that your having an erratic arc when you start to weld the reason being is when you weld aluminum you should ball up the end of your tungsten and maybe use a pure tungsten electrode to get a better result of weld bead. Thanks.

[evangelon2]

hi, I picked up a Super200P last month Getting ready to fire it up this weekend for the first time. I've heard that they can be problematic. Overall how has the machine treated you? What are the most common problems you've run into? (I imagine you can set the spark gap with a spark plug feeler gauge if you knew the proper gap) thanks for showing your settings!

[hrlawrh103]

how about not using paper towel with your acetone, cleanliness is critical for any load critical jobs, not cans i admit. try using pure cotten lint free cloth like for spray painting prep

[WDZaphod]

Thanks for this! Just learning how to weld, and I'm really impressed abt. what you do!

[thewelderdude]

Instead of the rare earth blends, try a 2% Lanthanated electrode. They will take more abuse than all the other types of electrodes and work awesome on AC and DC.

[JuryDutySummons]

Awesome. I always figured that metal like that was too thin to weld by hand.

[loserspwn420]

and btw love the video never thought of practicing on aluminum cans, robotics team is starting up soon and im shooting for the welders position. thanks!

[loserspwn420]

what material is the filler rod made of?

[Barnekkid]

Very interesting.

[TexasWhitetails1]

10:56 to skip the bullshit and get to the welding

[Just1Spark]

Genius welding table! A table saw! Thanks! I have a junk one laying around. Didnt even think of it!

[geweldigaum]

I like how you have an obviously well equipped shop and yet your welding table is a table saw.

[SuperMrAusten]

3 flow meters??? why

[DjViOd]

So this is essentially soldering but more difficult.