• 1 x STAHLWERK MIG MAG 200 Pulse Pro Digital
• 1 x Professional MIG welding torch AK-15 / hose package 3 m with Euro central connection
• 1 x Professional MIG MAG welding torch AK25/MB25 for aluminum, 3 meters with Euro central connection
• MIG MAG wear parts set aluminum for AK25/MB25
• MIG MAG premium aluminum welding wire ER4043 Si5 1.0 mm S200/D200 2 kg
• 2 x wire guide rolls U-shape 1.0/1.2 mm
• 2 x wire guide rolls V-shape 0.6/0.8 mm
• 2 x wire guide rollers 0.8/1.0 mm (pre-assembled)
• 1 x gas connection hose with quick coupling 5 m
• 1 x quick coupling gas pressure reducer incl. O-seal
• 1 x contact tip 0.6/0.8/1.0 mm each
• 1 x contact tip AL 1.0 mm
• 1 x earth cable 3 m
• 1 x slag hammer
• 1 x installation wrench
• 1 x wire brush
• 1 x protective cover for the Stahlwerk MIG MAG 200 Pulse Pro

What to Remember When MIG Welding Aluminium (Featuring the Stahlwerk MIG MAG 200 Pulse Pro)

MIG welding aluminium can produce strong, clean, visually impressive welds — but only when it’s done with the correct setup, correct parameters, and the right machine. Aluminium behaves very differently from mild steel or stainless steel: it’s softer, conducts heat faster, and requires a very precise welding arc to achieve good penetration without burning through.

Whether you’re new to aluminium MIG work or looking to sharpen your technique, there are several key things worth remembering, especially if you’re using an advanced machine like the Stahlwerk MIG MAG 200 Pulse Pro.

1. Cleanliness Is Everything

Aluminium forms an oxide layer almost instantly when exposed to air. This oxide layer melts at a far higher temperature than the aluminium beneath it, which leads to poor fusion, porosity, and weak welds.

Before welding:

• Remove the oxide layer with a stainless steel wire brush (only for aluminium).

• Degrease with acetone or an aluminium-safe solvent to remove oil and contaminants.

• Clean the joint itself as well as the surrounding material.

Starting with a perfectly clean surface is one of the biggest factors in achieving a smooth, defect-free aluminium weld.

2. Use the Right Wire and Filler Alloy

The most commonly used MIG aluminium wires are:

• ER4043 – Excellent flow, less crack-sensitive, ideal for general fabrications.

• ER5356 – Stronger, stiffer, better for structural work and marine environments.

Because aluminium wire is soft, feeding becomes more challenging. This is one of the reasons the Stahlwerk MIG MAG 200 Pulse Pro is a good match – its stable wire feed system and pulse technology help reduce burn-backs and wire deformation.

3. Choose the Correct Shielding Gas when using the Stahlwerk Mig Mag 200 Pulse Pro

Aluminium MIG should always be welded with 100% Argon. Anything else — CO₂ mixes or Ar/CO₂ blends used on steel — will produce poor penetration and excessive spatter.

For thicker materials, some welders may add helium to improve penetration, but for most fabrication work, especially in Northern Ireland and the UK, pure Argon is the standard.

4. Push, Don’t Pull

For aluminium MIG welding, you always:
Push the torch
Push the arc
Push the shielding gas onto the weld pool

Dragging or pulling leads to:

• Dirty welds

• Inadequate gas coverage

• Increased porosity

• Poor bead appearance

Keeping a push angle of around 10–15 degrees is ideal.

5. Keep Travel Speed High

Aluminium absorbs heat very quickly. If you move too slowly:

• You risk burn-through

• The weld becomes excessively wide

• Distortion increases

• The bead can sag or collapse

Aim for a fast, consistent travel speed — and this is where the pulse function on the Stahlwerk MIG MAG 200 Pulse Pro becomes a major advantage.

The pulse technology helps:

• Control heat input

• Improve penetration

• Reduce the chance of distortion

• Produce cleaner, smoother beads

This makes aluminium welding far easier for both beginners and experienced fabricators.

6. Use the Correct Wire Feeding Setup – Stahlwerk MIG MAG 200 Pulse Pro

Because the wire is so soft, aluminium MIG requires special feeding considerations:

• Use a Teflon/PTFE liner

• Use U-groove drive rollers

• Keep your torch lead as straight as possible

• Avoid long torch cables

The Stahlwerk MIG MAG 200 Pulse Pro is well suited for this: its wire feed system runs smoothly and consistently, helping prevent bird-nesting and feeding jams — two of the most common issues when welding aluminium.

7. Preheat May Help (But Isn’t Always Needed)

For thicker aluminium (6mm+), preheating can help stabilise the weld pool, reduce cold lap, and improve penetration. A preheat temperature of 80–120°C is usually enough.

However, for thinner sections or when using pulse MIG:

• Preheat is not always necessary

• Too much heat can actually create more distortion

Pulse MIG, as found on the Stahlwerk 200 Pulse Pro, reduces the need for preheat by delivering controlled bursts of energy to the arc.

8. Fit-Up Must Be Tight

Aluminium does not tolerate gaps well. Even a small gap can cause:

• Burn-through

• Excessive filler usage

• Ugly welds

Ensure joints are clamped tightly with good, consistent fit-up. The more exact the preparation, the easier the weld.

9. Expect Aluminium to Move — Control Distortion

Because aluminium conducts heat rapidly, it also distorts more than steel. Use:

• Strong clamps

• Tack welds at multiple points

• Pulse mode to reduce overall heat input

Good technique combined with the right machine can significantly reduce distortion.

10. Use a Machine That Supports Aluminium Properly – Stahlwerk MIG MAG 200 Pulse Pro

The Stahlwerk MIG MAG 200 Pulse Pro is an ideal machine for aluminium MIG because it offers:

• Pulse and double pulse modes

• Stable, accurate wire feed

• Excellent arc control

• Preset synergic programs

• Low-spatter aluminium performance

For fabricators, vehicle repair shops, general welding workshops, or anyone adding aluminium capability, the  Stahlwerk MIG MAG 200 Pulse Pro gives a professional result without needing a high-end industrial unit.

View our full range of Stahlwerk products here 

View our full range of MIG MAG Welders here