If you are in the position where you have aluminum tools or parts that have become damaged by cracks or a broken joint, consider welding the item with a TIG welder. This list of steps and suggestions for how to complete a successful aluminum repair can be a handy guide. Read through it and keep it around for reference in the future.

First, you should consider whether or not the damaged item in question really merits repairing. Is the tool or part easily and inexpensively replace. If this is the case then you may want to replace it rather than repairing it. Because, although TIG welding is an effective process for aluminum repair, it is tedious and time consuming to do it right and ensure a strong weld that will actually last and hold up under stress.

GTAW and TIG welding are both acceptable forms of welding for aluminum repair. However, we will refer only to TIG welding in this article. Many of the steps for preparation of aluminum are universal and can be translated.

When selecting your welding equipment, be advised that you will have to use a power supply with high frequency capabilities. All machines that are AC/DC will have this option built in. In the event that you have only an AC machine, you may require an additional high-frequency component that can be added on.

Next, this type of repair does not usually require more than 80-100 amps. A good setup is a 200-amp power source paired with a 200-amp air or water-cooled TIG torch. Additionally your power source should have post flow capabilities, which will help prevent contamination of the tungsten and weld puddle.

Joint preparation:

Do not skip the following steps or rush through them. Correct joint preparation is the most important step in aluminum repair. If a joint is not prepared properly, the end result will be a weak weld and frustration, because it will likely break again interrupting your work and wasting your previous time spent fixing it in the first place.

1. Disassemble and remove the damaged part if necessary. The smaller area you have to deal with the better. Also, you won’t want to risk damage to surround components during the repair process.

2. Clean out the joint using a stainless steel wire brush specifically made for aluminum. Removing any dirt and oxides present is a very important step to ensure proper joint fusion.

3. Using a hand grinder or a bench grinder, bevel the crack down to a “V” halfway through the depth of the aluminum. Next, tack weld the joint together and repeat these steps on the opposite side. If you are only able to access one side of the piece, bevel to a depth of 70-80 percent and then tack it.

4. Finally, clean the damaged item with aluminum cleaner such as Xero Tri-Cleaner/Degreaser. It is important to remove all grease, impurities, and moisture from the weld joint. Don’t forget to clean both sides of the joint.