Aluminium and Alloy TIG Welding Course

Lesson 1 • Tungsten Electrode Selection

Explains electrode types, geometry, and preparation methods specific to aluminium welding. Correct electrode choice directly affects arc stability and bead quality.

Lesson 2 • Equipment and Machine Setup

Identifies every component of a TIG welding system and explains correct machine configuration. Prepares students to set up equipment before any live welding begins.

Lesson 3 • TIG Welding Process Overview

Covers the physics of the TIG arc, shielding gas role, and welding heat input control. Establishes the conceptual base for all subsequent technique chapters.

Lesson 4 • Shielding Gas Fundamentals

Covers argon and helium properties, flow rates, and contamination risks. Correct gas selection is critical for oxide cleaning and weld quality on aluminium.

Lesson 1 • Alloy Identification Methods

Teaches visual, chemical, and spark-test methods for identifying unknown aluminium alloys. Field identification prevents costly filler metal mismatches.

Lesson 2 • Effects of Heat on Aluminium Alloys

Covers heat-affected zone softening, grain growth, and sensitisation in aluminium. Understanding these effects guides preheat and interpass temperature decisions.

Lesson 3 • Physical Properties of Aluminium

Examines thermal conductivity, oxide layer behaviour, and low melting point implications. These properties explain why aluminium demands different technique than steel.

Lesson 4 • Weldability of Common Alloys

Rates weldability of key alloy series and identifies cracking-prone compositions. Students avoid selecting incompatible base and filler metal combinations.

Lesson 1 • Joint Design for Aluminium

Covers butt, T, lap, and corner joint geometries with aluminium-specific groove angles and root openings. Joint design affects weld penetration, weld distortion, and filler consumption.

Lesson 2 • Fit-Up and Fixturing Techniques

Explains tack weld placement, clamping, and backing bar use to control weld distortion during welding. Proper fixturing maintains dimensional accuracy in finished assemblies.

Lesson 3 • Preheat and Interpass Temperature Control

Defines when preheat is required for thick sections and how to measure and maintain interpass temperature. Thermal management prevents cracking and controls weld distortion.

Lesson 4 • Aluminium Surface Cleaning Methods

Details mechanical and chemical cleaning sequences to remove oxide and hydrocarbon contamination. Clean surfaces are the single most important factor in aluminium weld quality.

Lesson 1 • AC Balance Control Settings

Teaches how to adjust the electrode-positive percentage to balance oxide cleaning against weld penetration and electrode life. Students dial in balance for different alloys and thicknesses.

Lesson 2 • Why AC Current Is Required for Aluminium

Explains the cathodic cleaning action of the electrode-positive half-cycle and its role in breaking the oxide layer. This principle justifies every AC parameter decision that follows.

Lesson 3 • AC Frequency Control Settings

Covers how increasing frequency narrows the arc cone, improves directional control, and reduces welding heat input. Frequency tuning is essential for thin material and precise welds.

Lesson 4 • First Beads on Flat Plate

Guides students through running stringer beads on flat aluminium plate with correct torch angle and weld travel speed. Bead appearance is used as diagnostic feedback for parameter adjustment.

Lesson 1 • Welding Thin Aluminium Sheet

Addresses burn-through prevention, heat sink use, and pulse settings for material under 3 mm. Thin sheet welding requires precise amperage control and fast weld travel speed.

Lesson 2 • Torch Manipulation and Travel

Covers forehand technique, torch oscillation, and consistent weld travel speed for aluminium. Proper manipulation controls heat distribution and prevents burn-through.

Lesson 3 • Welding in Horizontal and Vertical Positions

Adapts flat-position technique to out-of-position welding where gravity affects the molten puddle. Students control puddle sag and achieve full fusion in all positions.

Lesson 4 • Filler Rod Addition Techniques

Develops consistent dip technique, rod angle, and feed rhythm to produce uniform ripple patterns. Filler control directly determines bead profile and fusion quality.

Lesson 1 • Diagnosing Pulse Parameter Problems

Teaches how to read bead defects as diagnostic signals for incorrect pulse settings. Systematic troubleshooting reduces rework and improves first-pass quality.

Lesson 2 • High-Frequency Pulse Applications

Explains how high-frequency pulse stiffens the arc, improves directional control, and refines grain structure. Applications include aerospace components and precision fabrication.

Lesson 3 • Pulse TIG Principles and Parameters

Explains peak current, background current, pulse frequency, and duty cycle and their combined effect on the weld puddle. These four parameters govern all pulse TIG decisions.

Lesson 4 • Pulse Settings for Thin Aluminium

Applies pulse parameters specifically to material under 3 mm to minimise weld distortion and burn-through. Students set up and verify pulse parameters before welding thin assemblies.

Lesson 1 • Non-Destructive Examination Methods

Introduces dye penetrant, radiographic, and ultrasonic testing methods applicable to aluminium welds. Students understand when each method is required and what it detects.

Lesson 2 • Dimensional and Weld Distortion Assessment

Teaches measurement of weld distortion, angular change, and shrinkage against engineering tolerances. Dimensional control is critical in structural and precision aluminium assemblies.

Lesson 3 • Weld Repair and Rework Procedures

Covers grinding, back-gouging, and re-welding procedures for defective aluminium welds. Proper repair technique restores weld integrity without introducing new defects.

Lesson 4 • Visual Inspection of Aluminium Welds

Establishes visual acceptance criteria for bead geometry, surface finish, and cleaning zone appearance. Visual inspection is the first and most immediate quality gate after welding.

Lesson 1 • Welding Procedure Specification Basics

Explains the essential variables, supporting documentation, and qualification testing required in a welding procedure specification. Students read and follow a WPS correctly.

Lesson 2 • TIG Welding Aluminium Pipe and Tube

Covers joint preparation, purging, and positional technique for aluminium pipe and tube welding. Pipe welding demands mastery of all previous positional and pulse skills simultaneously.

Lesson 3 • Destructive Testing for Qualification

Covers bend, tensile, and macro-etch tests used to qualify aluminium TIG welding procedures. Understanding test requirements guides welders in producing qualification-ready welds.

Lesson 4 • Welding to Industry Quality Standards

Introduces acceptance criteria from structural, aerospace, and pressure vessel fabrication standards for aluminium welds. Students align their work with professional quality benchmarks.