One of the misconceptions regarding aluminum is that it is difficult to weld. This is not necessarily the case. The thing is, aluminum only needs a special kind of welding equipment, such as a pulse MIG welder.
That being said, we've researched the top eight pulse MIG welders for aluminum. As a bonus, we will also give a bit of background about aluminum welding and the pulse MIG welder.
Reviews of Best Pulse MIG Welder for Aluminum
Solary Inverter Aluminum Pulse MIG Welder
Equipment ||Inverter Aluminum Pulse
MIG Welder||59.4 lb ||54 x 29 x 52.3 in.|
The Solary Inverter Aluminum Pulse MIG Welder can work on various materials such as aluminum, galvanized steel, stainless steel, steel, HSS high strength steel, and its alloys. It is also perfect for soft wire like Alsi12 or Alsi5, making it a top choice for car enthusiasts and automotive repair projects.
This cheap pulse MIG welder (only less than a thousand bucks) has double-pulse technology—technology developed to handle aluminum welding projects.
This welder is equipped with advanced IGBT (insulated-gate bipolar transistor) inverter technology, synergic MIG programs, and the updated PWM (pulse width modulation) control technology. The downside is that the machine is not made for heavy industrial works.
HZXVOGEN HBM2280 Pulse MIG Welder
|H HZXVOGEN ||HBM2280 ||33.3 lb ||19 x 14.5 x 11 in.|
The HZXVOGEN HBM2280 Pulse MIG Welder is perfect for home and automotive repairs. It is a lightweight, cheap pulse MIG welder (only costs below 500 bucks) that can also weld iron and stainless steel effortlessly.
This welder is user-friendly with a more comprehensive digital display and can operate in dual voltage. As a safety feature, it has an integrated smart chip that automatically turns off the machine when it is overheating.
The HZXVOGEN HBM2280 Pulse MIG Welder package includes a graphite wire feed tube, hose clamps, welding brush and hammer, electrode holder, earth clamp, gas tube, and tungsten.
Reboot MIG Welder Aluminum 2T/4T Pulse Flux Core Welding Machine
|Reboot||MIG200DP Pulse MIG Welder||35.5 lb||19 x 15 x 14 in|
The Reboot MIG200DP 24T/4T Pulse Welder is designed for the average welding hobbyist. Like the previous welding machines, this one is lightweight and inexpensive (under 500 bucks) but doesn't compromise quality for the price.
The Reboot MIG200DP Welder incorporates smooth welding process technologies, such as a digital DSP control system for precise welding control and arc stability and a user-friendly interface for easy operation.
Lastly, it makes welding aluminum neater and produces high-quality weld formations. The downside of this welder is that the instructions in the manual aren't detailed, so it might be difficult to grasp for some. In addition, there were reported issues about wire-feeding complications and the absence of arc.
2019 Everlast PowerMTS 251Si Pulse MIG TIG Stick 250AMP Multi-Process Inverter Welder
|Everlast||PowerMTS 251SI||80 lb||25 in × 11 in × 18 in|
The Everlast PowerMTS 251SI Pulse MIG/TIG/Stick Welder is made with multi-processing welding features for your convenience. It's a great machine for welding professionals and hobbyists alike, as it is constructed for ease of operation.
First of all, the POWERMTS 251SI is a multi-process inverter welder, which means you get to choose between MIG, Pulse MIG, TIG, or stick welding. It is especially well-performing in MIG and flux core. Moreover, it provides specific and high-quality components like torches for each welding process.
For notable lowlights, it's a heavy machine and doesn't come with a parameter chart, which can be tough for beginners. It also comes at a higher price, albeit cheaper than the big brands. So instead of getting a Lincoln MIG welder, you can save a hundred or more bucks with this machine.
Hobart Handler 500559 140 MIG Welder
|Hobart||Handler 140 500559||57 lb||19 x 11 x 13 in|
If you're looking for an easily-operated machine to work on tough aluminum, the Hobart Handler 500559 140 MIG Welder is a perfect tool for your DIY, small workshop, maintenance, repair, automotive, hobby, or farm welding work.
Some of its features include a 5-position voltage control to fine-tune the arc for smooth and stable welding arc; a 110V outlet that allows you to work on various welding projects; and a thick and solid external construction that's easy to work with.
When it comes to results, Hobart is a strong candidate. However, you might encounter problems with the quality and setup of some components included in the package (e.g., spool wire). In addition, it's limited to 1/4-inch steel due to the outlet, so you can't weld on thicker metals as they need more than 110V. Still, this has some great value for the price.
YesWelder MIG-250 Pro Aluminum Welder
|YesWelder||MIG-250PRO-AL MIG Welder||32.8 lb||20.38 x 16.5 x 11.13 in|
Looking for an affordable machine (less than 600 bucks) to help fix items in your small garage or commercial establishment? You might like the YesWelder MIG-250 Pro Welder. It almost works for any aluminum, steel, or stainless steel welding job that you might have.
The MIG-250 Pro features two operation options: synergistic & manual. The synergistic mode automatically connects the power source, feeder, and gun and makes welding easier for beginners. Additionally, this YesWelder machine is also multi-purpose: you may use it for gas MIG, gasless MIG, stick or lift TIG welding.
Meanwhile, the notable downside is that some components aren't included and compatible with the machine. For example, it doesn't come with a regulator and a TIG torch and isn't compatible with a spool gun. Nevertheless, if the lowlights won't interfere with your project, this product has a good value for the price.
MYYWELD Portable MIG 160 Welder Machine
|MYYWELD||MVM-160||26.9 lb||16.6 x 7.2 x 9 in|
How would you like a mighty little welder for your aluminum workpiece? The MYYWELD Portable MIG 160 Welder is a compact and versatile machine for entry-level welding enthusiasts. It's suitable for metals like aluminum, iron, stainless steel, and carbon steel. You can use it for basic DIY, maintenance, repair, metal fabrication, or making road and farm equipment.
One of the MVM-160's best features is its compact and lightweight design, which will help you reduce the hassle of maneuvering equipment. It also incorporates an easily understandable and operated digital display. Want more? It features IGBT technology for stability and multi-welding properties; you can use it for MIG, lift TIG, stick, or MMA welding projects.
Compared to the previous welders we discussed, this is the most inexpensive one on the list. However, the MVM-160 lacks proper instructions, which can be difficult for those still learning the ropes.
Tooliom 135A Inverter MIG Welding Machine
|Tooliom||TL-135M||17.36 lb||17 x 13 x 10 in|
Cheap and simple, the Tooliom 135A Inverter MIG Welder is a solid machine for DIY welding enthusiasts and beginners. It's not complicated to operate, but it's multi-purpose, so you learn a lot from it.
As briefly mentioned, it's good for multiple welding projects. You can use it for MMA, flux MIG, and lift TIG welding on carbon and stainless steel. Moreover, it is made with compact construction in mind, so it's a more convenient tool than the pricey and heavier welders in the market.
However, cheap and simple can be a disadvantage too. Some users look for components such as a TIG gun or shielding gas port, but this machine doesn't come with one. For some, the wire feed cable is too short and not easy to control, so you might want to consider these pointers when making a purchase decision.
What is a Pulse MIG Welder?
A Pulse MIG Welder is an equipment that can produce a specific type of welding transfer method called pulsed MIG. Overall, there are four welding transfer modes, and the other three are short circuits, globular, and spray arc.
In pulsed MIG welding, the machine's power source instantly switches between a high peak current and a low background current. The high peak current promotes better fusibility, while the low background current reduces the burn-through and warping. This is why this type of welding transfer mode can handle aluminum's lack of fusion and high thermal expansion.
Benefits of Pulse MIG Welder for Aluminum
This welder addresses several issues when working on aluminum fabrications:
- It produces smooth and near spatter-free welding.
- It prevents warping or burn-through because of lower heat inputs.
- It decreases wire feeding issues such as burnback and bird-nesting.
- It produces a lower level of fumes.
- It lets you perform out-of-position welds.
5 Pulse Welding Tips
Here are a few pulse welding tips to get you started:
- Ensure that the parent material or base metal is free from various impurities such as grease, dirt, paint, rust, and plastic.
- In pulsed MIG, the gas settings must be 90% argon and 10% CO2. This mixture makes it possible for the pulse MIG welder to produce a pulsed spray or spray arc.
- Before working, check what type of wire you are using and ensure that it matches the program you've set in the welding machine. For example, if the spool is a .045 in. wire, the machine's display should reflect that type of wire, which is .045 in.
- Adjust the wire feed speed and arc length accordingly to successfully create a spatter-free weld.
- The sound that you should hear when you are pulse MIG welding is a nice smooth, consistent buzz, and not popping, crackling, spitting, and spattering sounds.
The pulse MIG welder is the best welding buddy you can count on when working on challenging base metals like aluminum. It addresses the common issues associated with aluminum welding, as mentioned above. Thus, it helps increase your productivity, reduce rework, and deliver high-quality welds.