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A 115-volt welder can handle aluminum up to an eighth of an inch thick (3 mm) with adequate preheating, and a 230-volt machine can weld aluminum that's up to a quarter of an inch thick (6 mm). Consider a machine with an output greater than 200 amps if you will be welding aluminum daily.
4. Clean the aluminum before welding, to remove the oxide layer. Use a stainless steel wire brush used only for cleaning aluminum. 5. Fill the crater at the end of the weld to avoid a crack. One way to do this is to dwell in the weld pool for a second at the end of the weld.. Clean the aluminum before welding, to remove the oxide layer. Use a stainless steel wire brush used only for cleaning aluminum. 5. Fill the crater at the end of the weld to avoid a crack. One way to do this is to dwell in the weld pool for a second at the end of the weld.