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I just picked up a Lincoln Square wave 175 TIG and having problems on AC welding aluminium. Everything is good on DC welding steel but on AC the Arc is unstable and leaving black deposits. The electrode seems to be overheating almost straight away .
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To obtain the best results while MIG welding automotive sheet metal, proper fitment and cleanliness of the metal are essential. Spend the time to make the new panel or panel patch a perfect fit. Ideally, there should be a 1/32" gap between the patch and the body panel.
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Still, it’s possible to weld thin sheet metal using the MIG (GMAW), TIG (GTAW), and stick (SMAW) processes. But MIG and TIG provide the best results. This article will teach you how to weld thin gauge metal using each arc welding process and present the common pitfalls beginners make.
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