Tig Welding 1/16 Inch Aluminum (Suggested Settings)

Tig welding thin metal is not an easy task especially in case of aluminum. You may burn-through the metal easily. 1/16 inch aluminum is thinner and you must set your tig machine and other accessories to comply with the application.

We will discuss the correct settings of your tig welder to weld 1/16 inch aluminum alloy.

Types of joint

  • Butt Joint
  • Lap Joint
  • Corner Joint
  • Fillet Joint

We will discuss the settings of tig welder for each joint.

Butt Joint

It is simple form of welding joint where two pieces of work metal is placed side by side and welded along the join area.

Butt Joint

To butt weld 1/16″ aluminum follow the settings bellow-

Tungsten DiameterUse pure tungsten (green) for butt welding 1/16 inch aluminum. You may also use 2% ceriated (grey) tungsten. For inverted tig welder weld with 2% ceriated tungsten at 100hz frequency for best result
Torch CupUse water cooled torch (1/4-3/8″) if you are using more than 250amp welder and may use ceramic cup torch for welder under 200amp.
Filler MetalFiller metal you should use is 1/16 inch or 1.6mm.
PolarityAc tig would be better for butt welding 1/16 aluminum
AmperageRanges from 65 to 75 amps
GasArgon is better for butt welding 1/16 aluminum but for thicker metal combination of argon and helium would be best. Set the gas flow rate at 15cft.
Travel SpeedYou should be slow at the beginning of welding then slowly you may increase the speed. We recommend to weld 12inch/minute.
Position Flat, Horizontal and Vertical
This is approx. manual settings. May differ based on welder company. See the specs.

Lap Joint

Lap joint is basically placing two pieces of metal in overlapping style and weld to join them together. Normally used in joining two different types metal.

lap Joint

To lap weld 1/16″ aluminum follow the settings bellow-

Tungsten DiameterSame as butt joint
Torch CupSame to butt joint
Amperage Ranging from 60-70
Gas Gas & flow rate would be same as butt joint that is argon at 15cft.
Filler Electrode1/16 inch
Weld Speed10″/minute

Corner Joint

In corner joint, one piece of metal is placed over another pieces corner perpendicularly like English alphabet ‘L’. Then welded the join area for attach them together.

Corner Joint

To corner weld 1/16″ aluminum follow the settings bellow-

Amperage Ranging from 55 to 65
SpeedShould be 12inch per minute
Other settings would be same as butt and lap joint.

Fillet Joint

In Fillet joint one piece of metal is place perpendicularly or in 90 degree angle over another metal. Then two pieces are welded together.

Fillet Joint

To fillet joint 1/16″ aluminum follow the settings bellow-

Amperage From 55 to 75
Speed 10″per minute
Other settings are same as butt joint.


1/16 inch aluminum is thinner metal. You must be careful about welding settings and most importantly you must pay attention to welding speed and amperage. You can see in butt, lap, fillet and corner joint requirements that amperage and speed of welding changes but other settings remains the same in most of the cases.

Note: wear proper safety equipment while tig welding and try not ever to touch the welded metal after welding.


  • James Smith

    This is James Smith, a Hobbyist welder, welding since my 15th birthday. My father was a professional welding mechanic at a garage and used to take me to garage. My love for welding started then and I learnt basics from my father. At my 15th, my father gifted me a stick welder and my journey to become a welder began. Gradually I accustomed to welding and mastered at tig welding.

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