The first impression of aluminum is that since it is pliable and easily manipulated, it should be easy to weld. In reality, it is considered to be the most difficult metal to weld since it is an alloy and therefore mixed with other metals. Some have even called welding with aluminum a “nightmare.”

Because it is such a soft metal, special tools are needed to make a good weld. Welding with aluminum releases aluminum oxide particles into the air. These are toxic and can result in respiratory and lung diseases. A respirator must be worn for all welding processes when welding aluminum.