Materials
Can you weld aluminium with a MIG welder?
Quick answer
Yes, with two conditions: the machine supports a spool gun or has an aluminium-capable drive, and you use 100% argon with aluminium wire (ER4043 or ER5356). Soft aluminium wire jams in long conventional MIG torch liners — that's what the spool gun solves. Thickness under ~1.6 mm belongs on TIG.
Setup checklist
- 100% argon gas — never an argon-CO2 steel mix
- Spool gun (or short, straight, correctly-sized liner)
- ER4043 wire (general purpose) or ER5356 (higher strength)
- U-groove drive rolls — V-rolls crush soft ally wire
- Fast travel: aluminium's oxide hides a pool that's already falling through
Technique differences from steel
Aluminium conducts heat away fast, so you run hotter and faster than steel of the same thickness, and the puddle is deceptive — it looks dull under the oxide until it suddenly drops. Push the gun at a 10–15° lead angle to keep the shield ahead of the pool. For sheet, cosmetic and joints that matter, AC TIG remains the quality benchmark.