TIG Aluminum Welding Course

Lesson 1 • TIG Process Principles

Covers the physics of the tungsten inert gas arc and how shielding gas protects the weld pool. Anchors all subsequent technique instruction.

Lesson 2 • Electrical Fundamentals for TIG

Explains AC vs. DC polarity, amperage, and voltage as they apply to TIG welding. Builds the electrical literacy needed to set machine parameters correctly.

Lesson 3 • Equipment Identification and Setup

Identifies every major component—power source, torch, gas system, and foot pedal. Correct setup prevents equipment damage and unsafe conditions.

Lesson 1 • Filler Metal Selection

Matches filler alloys to base metal for strength, crack resistance, and corrosion performance. Correct filler choice is critical before any arc is struck.

Lesson 2 • Base Metal Cleaning and Preparation

Teaches mechanical and chemical methods to remove the oxide layer and surface contaminants. Inadequate cleaning is the leading cause of porosity in aluminum TIG welds.

Lesson 3 • Aluminum Alloy Families

Surveys the major aluminum alloy series and their weldability ratings. Knowing alloy composition prevents cracking and guides filler selection.

Lesson 1 • AC Frequency Settings

Covers how increasing frequency narrows the arc cone and concentrates heat. Frequency tuning enables precise control on thin and thick sections alike.

Lesson 2 • Tungsten Electrode Preparation for AC

Specifies pure tungsten and zirconiated tungsten selection and the balled-tip formation process for AC welding. Correct electrode prep stabilizes the arc on aluminum.

Lesson 3 • Shielding Gas Selection and Flow

Compares pure argon, helium, and argon-helium blends for aluminum TIG applications. Correct gas type and flow rate prevent contamination and porosity.

Lesson 4 • Amperage and Slope Controls

Details upslope, downslope, and pulse settings that manage heat input at weld start and end. Proper slope settings prevent craters and burn-through.

Lesson 1 • Travel Speed and Heat Management

Connects travel speed to heat input, bead width, and distortion on aluminum. Students practice adjusting speed in real time using foot pedal feedback.

Lesson 2 • Torch Grip and Body Positioning

Establishes ergonomic grip, arm bracing, and line-of-sight positioning for stable torch control. Poor posture causes arc length variation and fatigue.

Lesson 3 • Arc Length and Torch Angle

Defines optimal arc length for aluminum and the work and travel angles for each joint type. Consistent arc length is the single greatest factor in bead quality.

Lesson 1 • Butt Joint in Flat Position

Covers root pass, fill pass, and cap pass sequencing for a flat butt joint. Proper joint preparation and pass sequencing prevent lack-of-fusion defects.

Lesson 2 • Horizontal Position Butt and Fillet

Adapts flat-position technique to the 2G and 2F positions where gravity affects the puddle. Students learn to compensate torch angle and travel speed for horizontal welding.

Lesson 3 • Visual Inspection and Self-Assessment

Introduces visual weld inspection criteria—porosity, undercut, overlap, and incomplete fusion—applied to student coupons. Self-assessment accelerates skill development.

Lesson 4 • Stringer Beads on Flat Plate

Practices straight stringer beads on flat aluminum plate to build muscle memory for speed and arc length. This is the baseline skill for all subsequent joint work.

Lesson 1 • Overhead Position Fundamentals

Covers the unique torch angle, shortened arc length, and reduced amperage required for overhead welding. Overhead is the most physically demanding position.

Lesson 2 • Vertical Butt and T-Joint Welds

Applies vertical technique to butt and T-joint coupons in the 3G and 3F positions. Multi-pass sequencing in vertical requires precise interpass temperature control.

Lesson 3 • Overhead Butt and Fillet Welds

Produces 4G butt and 4F fillet welds on aluminum coupons to acceptable visual standards. Consistent overhead performance demonstrates full positional competency.

Lesson 1 • Rolled Position Pipe Welding

Teaches welding in the 1G rolled position to build pipe technique before fixed-position challenges are introduced. Rolling keeps the puddle in the flat position throughout.

Lesson 2 • Fixed Position Pipe Welding

Addresses the 5G fixed position where the welder must transition through flat, vertical, and overhead zones on a single pass. This is the most complex positional challenge.

Lesson 3 • Tube Welding for Fabrication

Applies pipe skills to thin-wall aluminum tubing common in aerospace and automotive fabrication. Thin walls demand precise heat control and faster travel speeds.

Lesson 1 • Welder Qualification Preparation

Prepares students for formal welder performance qualification tests on aluminum. Understanding test requirements focuses practice on the skills that matter most for certification.

Lesson 2 • Systematic Troubleshooting Process

Provides a structured root-cause analysis method for recurring defects, linking symptoms to machine settings, technique, or preparation errors. Systematic thinking reduces rework.

Lesson 3 • Weld Defect Classification

Catalogs surface and subsurface defects—porosity, cracks, undercut, and incomplete fusion—with their root causes. Classification is the first step in systematic troubleshooting.

Lesson 4 • Non-Destructive Examination Methods

Introduces visual, dye-penetrant, and radiographic inspection methods applicable to aluminum welds. Understanding NDE methods helps welders produce welds that pass examination.