How to Weld Aluminum with a Stick Welder at Home: Welding Hacks

If you are a professional welder or fond of welding, you must wonder how to weld aluminum with a stick welder? Welding aluminum metal using this machine is not cumbersome, and it’s a process that requires less effort.

By reading this review post, you are in a better position than most people lacking insights on making significant aluminum welds. A stick welder is a lightweight welding machine and does great weld, especially on both thin and thick metals.

Importantly, it’s suitable for outdoor works since gas-based welders don’t give robust results if you are welding under windy weather conditions. In this post, we will detail how to use a stick welder when it comes to welding aluminum metal.

Everything detailed here is factual and will make it possible to understand this machine better. Let’s get started, mate. We got you all along!

How to Weld Aluminum with a Stick Welder

Stick welding is an old form of welding and the good thing about it is its cheapness and suitability under different weather conditions. Stick welding is used in medium-sized shops and is great for beginners and can be used to conveniently weld aluminum metal.

When using the stick welder, users are advised to utilize a much powerful and directly affiliated welder. An aluminum electrode is also vital. Importantly, it’s crucial to weld in a fast manner and avoid excess links with the arc. By doing so, the aluminum material will bound fast.

Here is the Process for Welding Aluminum Using a Stick Welder Machine:

1. Ensure you Have Safety Gear

Safety is the most important thing to consider when it comes to welding using a stick welder. Ensure you follow all insights detailed in the user manual of the stick welder. Before welding, it’s vital to protect your eyes and body from UV light and sparks produced.

Wear long-sleeved attire to protect your body from these hot sparks. Also, ensure that you wear protective glasses to protect your eyes from harmful layers. Lastly, a helmet will ensure that your head is protected from prevalent garage or workshop flaws.

2. Cleaning the Aluminum Metal

Aluminum is a fragile metal and usually is affected by oxygen, which leads to the formation of aluminum oxide. Before embarking to weld, it’s important to remove this thin layer. If you can, try to avoid the formation of aluminum oxide.

To remove this layer, utilize a sharp tool or go for the sandpaper to get the best results.

3. Floor Clamping

The floor clamp should be included in the stick welder package. To install it correctly, plug it onto the welder and clamp it to work on the aluminum metal material.

4. Utilizing the Electrodes

Many electrodes exist, and you will be required to use one that complements well with the aluminum metal. As such, ensure you use electrodes that are suitable for welding aluminum to avoid doing a shoddy job. To better understand the right electrode, you need to grasp these important numbers.

First Two Numbers

Electrodes’ first two numbers show minimal tensile strength. An electrode with 60,000 psi strength will usually start at 60. By functionality, it needs to match correctly with aluminum metal.

Third Number

The third number in the electrode shows the right position for welding. Electrodes first number shows that it can be used under any position while the second shows it can only be used when on a flat based position.

Fourth Number

Shows the suitable current electrode. Also, it shows the aluminum coating suitable for welding.

5. Welding the Arch

Once you have set the suitable electrode onto the holder, start the welder. To hit the arc, start by placing the tip of a suitable welder electrode on the metal. Continue by dragging it while hitting a match. When the arch is harnessed, uplift the electrode slightly and pull it on the aluminum metal.

When the electrode sticks on the aluminum metal, continue by breaking it to have a slight twist. In the arc cuts, the suitable welding electrode distances are higher than the required level. Ensure its low to get the best results.

When a suitable arc is ignited, a frying meat sound should be heard. In case the sound is loud, then it’s high time you reduce the amperage level.

6. Moving Around the Aluminum-based Electrode

When the arch has been ignited, embark on moving the electrode over the joint to make the weld. Before changing the position of the electrode, it’s vital to ensure it’s placed under the right angle. A 15 or 30% angle directed in a vertical position is best.

By now, you have hit the electrode at the right angle, and you should embark to slowly move the electrode in a backward position. Don’t push the suitable electrode since the weld pool can be affected by slag and thus lead to porosity.

Importantly, ensure that you rest your hands on the elbow while at the same time making sure your hand is held on the electrode. Make a scan several times and then troubleshoot to ensure everything is working correctly.

It is a simple process that doesn’t utilize a lot of effort and makes it possible to form a strong weld. Although it may take time to learn how to use a stick welder, this method is one of the simplest and not expensive.

Also, you can follow insights detailed in the user manual to make great aluminum welds.

Required Tools when Using a Stick Welder Machine

When using a stick welder, it’s robust to be armed with the right tools to achieve the best job. Also, stick welder tools help to ensure that the technician’s health is protected.

Here are Notable Tools Required when Using the Stick Welder Machine:

Safety Accessories


Another important tools needed are earplugs and help to ensure extreme noise produced when welding doesn’t affect your eyes.

A Mask

A mask is also required and helps to protect users from dangerous fumes released when welding.

Safety Glasses

Safety glasses are essential to protect yourself from harmful rays released.

Welding Accessories

A Metal-based Brush

In case there are slags, when welding a metal brush will help to remove the unwanted substances. Brush the slag with ease to ensure a clean surface is left.

An Angle Grinder Tool

Helps when prepping and finalizing welds. Also, it can be used to remove accumulated rust and dirt around the work area. An angle grinder helps to cut through metal and is suited for thin ones.


Electrodes are inserted at the end of the welder, and current is passed through to make welds.

Cautions & Tips when Using a Stick Welder

A technician must ensure you are armed with tips and cautions when using this welding machine. Let’s look at some notable caution and tips concerning the use of stick welder.

Ensure that you wear glasses and gloves to avoid health concerns. Ensure you cover your skin completely and glasses protect you from being affected by harmful rays produced when welding. Your health is vital, and that’s why it’s important to be armed with these helpful gear tools.

When welding, ensure that you do so in a well open place so that welding fumes can be directed outside the work area. A well-ventilated area will ensure harmful fumes don’t accumulate in the work area. Ensure that you stop the stick welder when not at work.

By doing so, you prevent accidents prevalent with the stick welder. Falls in the work area can make the stick welder cut through your body parts. Ensure that you wipe away any spilled fuel that could be released by the stick welder. Also, keep all fasteners in place to ensure that everything is set in place.

When working with a stick welder, you should never at any time fuel when its operation. First, stop it and then proceed to fuel. Fueling when the machine is working can lead to fire, and that is why it’s robust to avoid adding more fuel when the machine is running.

Following all the above-mentioned cautions and tips will guarantee a safe environment that makes it possible to weld strong. Importantly, always wear protective gear to be safe health-wise.


Welding aluminum metal using the stick welder is not hard. A simple machine that is easy to use if you follow all information detailed in this review post. By following all details in this review, you can never go wrong when it comes to welding aluminum using a stick welder.

All content availed is correct and thoroughly researched to ensure that you get it easy when it comes to welding utilizing a stick welder. Stick welders’ are great machines that can make it possible for technicians to weld aluminum metal conveniently.

Achieve the best welding results by utilizing this versatile machine. This is the best machine currently available for aluminum metal users, and there is no reason you shouldn’t acquire one.

Leave a Comment