What happens if you stick weld aluminum with AC?
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  1. #1
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    What happens if you stick weld aluminum with AC?

    Since all the rods are labled for DC, I'm guessing it won't turn out great.

    What happens?
    1. You can never start an arc
    2. The rod burns straight through the alu.
    3. The weld never penetrates
    4. The weld looks fine, but will break as soon as a feather falls on it.
    5. The weld works just fine on AC, it's just a bit more difficult.
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  2. #2
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    Re: What happens if you stick weld aluminum with AC?

    I use GTAW

  3. #3
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    Jan 2006
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    Re: What happens if you stick weld aluminum with AC?

    I screwed around with some stick aluminum welding last year. The rods were old, but I dried them out a bit and gave it a go. I honestly can't remember what my setting were....I know I tried them all

    I just messed around with it for a hot second, I'd be interested in seeing some pics from guys with experiece in sticking aluminum! I've looked for pics before and haven't found any.

    Here's my crap, I did a few t-fillets:




  4. #4
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    Re: What happens if you stick weld aluminum with AC?

    Tried it, didn't like it. Much better results with DCEP and a lot more amperage than with steel of the same thickness. Be prepared for 1/8 rod to go away in less than 10 seconds.

  5. #5
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    Dec 2011
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    Re: What happens if you stick weld aluminum with AC?

    Centerline cracks there.

    I realize this is an old post.

    I tried some of those things a few years ago and ended up with pretty brutal results. The fumes from the flux smelled pretty damn corrosive.

    Then I jumped back onto my TIG machine and all was right with the world again.

  6. #6
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    Re: What happens if you stick weld aluminum with AC?

    Quote Originally Posted by Joshfromsaltlake View Post
    Centerline cracks there.

    I realize this is an old post.

    I tried some of those things a few years ago and ended up with pretty brutal results. The fumes from the flux smelled pretty damn corrosive.

    Then I jumped back onto my TIG machine and all was right with the world again.
    Dang!!!! This is an old post. 2009!!!
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  7. #7
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    Re: What happens if you stick weld aluminum with AC?

    I played with it for a short bit, old crusty rods, and had to move quick as anything. Definately not a go to choice, but if it's all you had they could get you out of a bind with some practice.
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  8. #8
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    Re: What happens if you stick weld aluminum with AC?

    Quote Originally Posted by SuperArc View Post
    Dang!!!! This is an old post. 2009!!!
    And on aluminum Stick welding of all the bad subjects to revive. Joshfromsaltlake get sent to penalty box!!!
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  9. #9
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    Re: What happens if you stick weld aluminum with AC?

    @Mike,

    I knew you could stick weld aluminum, but never saw it done before. That does not look too bad at all. Good job!


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  10. #10
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    Re: What happens if you stick weld aluminum with AC?

    I was only playing with some crusty old rods laying around. If I put a little more thought into it I could probably do alot better in time, thanks tho GAR These suckers burn FAST bro, almost to the point of being hillarious
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  11. #11
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    Re: What happens if you stick weld aluminum with AC?

    Quote Originally Posted by weldermike View Post
    I was only playing with some crusty old rods laying around. If I put a little more thought into it I could probably do alot better in time, thanks tho GAR These suckers burn FAST bro, almost to the point of being hillarious
    Mike, what polarity, machine and amp setting did you use? Also, what size and brand rods were they? You welds looked really good as far as SMAW aluminum goes. I don't think ive ever seen better.
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  12. #12
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    Re: What happens if you stick weld aluminum with AC?

    Quote Originally Posted by SuperArc View Post
    Mike, what polarity, machine and amp setting did you use? Also, what size and brand rods were they? You welds looked really good as far as SMAW aluminum goes. I don't think ive ever seen better.
    Those rods are All State rods that have been laying around for years. So old they looked like they had yeast infections They were 1/8 somewhere around 70amps I believe and I used a old Syncrowave on DCRP, not A/C
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