Aluminium MIG pulse welding has a unique set of challenges. It has a lower relative melting point than other metals, yet requires heat to ensure proper weld pool formation. One critical step while working with aluminium is the cleanliness of the parent metal. It is more sensitive to heat input and distortion than most other metals.

Traditional welding of aluminium usually required the use of an ACDC TIG welding machine. But with recent technological advancement, this has made Pulse MIG welding more viable in an application where increased production is highly achievable. All without sacrificing the quality or appearance of the results.

In Pulse MIG welding, the welding power-source rapidly and automatically switches between high peak current (Better fusibility) and a low background current (reduced heat and distortion). Pulse MIG welding machines can be used on Mild & Carbon steels, Aluminium, Stainless Steel, Copper, Brass and High tensile steels such as hardox and bisalloy type products.

Today, almost every plate boat builder and ship-building welder is a Pulse MIG welding machine. Due to these machines becoming increasingly portable, this enables safe handling and better access into engine rooms and small areas within the vessels.

Pulse MIG welding is widely used in the automotive industry. Most of the vehicle manufacturers recommend MIG welding processes for today’s aluminium-intensive vehicles. However, not all operators & repairers know the difference between standard MIG welding aluminium from Pulse MIG welding on aluminium…So let’s take a closer look at their differences.

Pulse MIG welding can be used to both thick and thin aluminium. On thicker sections, it helps minimize downtime for repositioning parts since it generates a cooler weld pool than traditional spray transfer process, making it usable in all welding positions.

By pulsing the current, the operator can control the heat input into the parts and weld thinner gauge material without burning through or warping the parts being welded.