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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.
How to weld aluminum to steel. You can weld aluminum to most other metals relatively easily via adhesive bonding or mechanical fastening. However, in order to weld aluminum to steel, special techniques are required. When metals such as steel, copper, magnesium, or titanium are directly arc welded to aluminum, very brittle intermetallic compounds start to form.