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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.
Dirty Welds: To avoid contaminating a weld push the weld away rather than dragging or pulling the weld towards yourself. Be sure to clean the aluminum properly before welding. Wire Burns (MIG): To avoid wire burns near the contact tip throughout the weld, keep an appropriate distance between the weld and the tip. Also, ensure you are using the correct tip sizes, liner, and wire for the particular job.