Guide to Aluminum Welding Resources and Products | MillerWelds

Everything You Need for Aluminum Welding

Whether you're new to aluminum welding or have been doing it for years, you need to efficiently make strong, good-looking welds. Aluminum welding isn't difficult, it's just different — with the right equipment and consumables, you can confidently weld aluminum all day.

Ask an aluminum specialist about your welding challenges.




Aluminum Welding Knowledge Center

Guide to Industrial Aluminum Welding — Beyond the Basics

Get answers to more advanced questions about aluminum MIG and TIG welding and some tips for industrial applications.
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Reducing Rework in Manufacturing: 5 Tips to Improve MIG Welding Sheet Metal

Learn how to reduce heat input and improve results when welding sheet metal, to reduce rework in manufacturing applications.
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Guide to Industrial Aluminum Welding — The Basics

Get tips for successfully welding aluminum, including prep, storage, process selection and handling common challenges.
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When Preheating Before Welding, How to Choose the Right Equipment

Air-cooled cables, a new heating tool for induction, deliver flexibility and efficiency for welding preheat.
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Best Practices For Proper Shielding Gas in TIG Welding

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How to Improve the Look and Quality of Aluminum TIG Welds

Learn more about using proper polarity, adjusting balance control and setting AC amperage independently when welding aluminum.
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Learn How Aluminum and Lightweight Materials are Changing Auto Body Repair

Changing fuel economy standards and materials used in vehicle design are placing new demands on collision repair shops.
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How to TIG Weld Aluminum, Plus MIG Weld, With One Multiprocess Welder

The Dynasty® 280 DX Multiprocess welder provides portability and ultimate versatility to weld many different materials.
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TIG Welding Anodized Aluminum with Advanced AC TIG Waveform Controls Speeds Production for Birdsall Marine Design

Miller Dynasty® 350's superior arc shaping capabilities cut welding time by 50 percent, improve weld quality and efficiency for Florida fabricator. Advanced AC TIG controls help cut through anodized aluminum much easier than older TIG technology.
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Choosing Between Plasma Cutting and Oxy-fuel Systems

Oxy-fuel and plasma cutting systems both have advantages and disadvantages. Learn more about how to choose the right one for your needs.
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Easy-To-Use Welding Technology Shortens Welder Training and Reduces Rework

Welding power sources are easier to use, with simplified interfaces and push-button changes. Learn more about new solutions.
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A Love of Racing Leads Jessica Johnston to Welding

Johnston isn’t fazed by being a woman in two male-dominated worlds: racing and welding. She plans to continue chasing her passions and doing what she loves. “You have to prove yourself — everybody wants to make sure that you know what you’re talking about,” Johnston says. “But I’m not going anywhere. It’s so much of a passion that nothing will deter me. Once you’re in the industry and people take...
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Welding Aluminum vs. Steel — Tips to Improve Your Results

Learn the key differences between welding aluminum vs. carbon steel so you can confidently weld aluminum.
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Weld Preheating on the Jobsite Made Easier

A new induction heating tool for jobsites allows contractors to insource preheating and bake out to reduce costs and save time.
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Advances in Aluminum Robotic Welding

Aluminum presents several challenges during the welding process, such as burn-through, warping or lack of fusion. Learn about robotic welding systems.
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Wire Feeders From Basic to Advanced — How To Choose the Right Feeder

Having the right wire feeder for the job can play an important role in reducing unnecessary downtime for addressing issues associated with poor wire feeding.
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Learn 5 Best Practices, Including Pulsed MIG, for Welding Different Materials

Learn more about welding technologies and processes, including pulsed MIG, that offer benefits for welding different materials.
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Guide to Pulsed MIG Welding in Manufacturing

See how a switch to pulsed MIG welding can deliver results such as reduced spatter and rework in your manufacturing operation.
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Aerospace Fabricator Reduces Power Draw, Improves Weld Performance with New Fleet of AC/DC TIG Welding Inverters

Ace Clearwater Enterprises, specialists in complex formed and welded assemblies for the aerospace and power generation industries, improved energy efficiency and weld performance by replacing a fleet of 23 transformer-based TIG welders with brand new AC/DC TIG inverters.
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Fan Manufacturer Standardizes on Pulsed MIG Welding for Aluminum

Pulsed MIG improves productivity, reduces reject rates and provides Greenheck with welding versatility not possible with older technology.
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Ron Covell Reviews the Dynasty 210 DX TIG Runner with Wireless Package

Ron Covell, owner of Covell Creative Metalworking in Freedom, provides a product review on the Miller Dynasty 210 DX TIG Runner with Wireless Package.
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Tips for Engine Repair Welding on 4 Common Materials

Choose the right filler metal and follow key best practices to overcome the welding challenges presented by some materials.
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8 Tips for Using a Plasma Cutter in Custom Car Builds

Ensure proper plasma cutter settings with a sample cut and use faster travel speeds for cleaner cuts. Read more plasma cutting tips.
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New Advanced Aluminum Welding System Spurs Production on Bollinger Shipyard's U.S. Coast Guard Fast Response Cutter (FRC) Contract

Before any of the U.S. Coast Guard’s Fast Response Cutter (FRC) patrol boats hit open water, they begin their journey up 60 miles of waterway through Bayou Lafourche in Lockport, La. That’s where Bollinger Shipyards builds the Coast Guard’s newest vessel for conducting search and rescue, drug and illegal immigrant interdiction, homeland security and mainland defense.
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Choosing What Filler Metal To Use for DIY Welding Projects

No matter the welding process or material, here are six questions to help determine what filler metal to use for DIY welding.
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7 Questions to Ask Before Purchasing a Welding Information Management Solution

Welding information management solutions can help companies address pain points by offering effective training, increasing productivity, reducing costs, enforcing proper weld sequence and preventing missed welds — among other benefits. Before making the investment, however, it is important to ask some key questions to ensure the best results.
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Addressing the Welder Shortage with Technology

There are welding technologies and solutions that can help companies find and train skilled welders faster — and make it easier for welders to complete high-quality welds once they are on the job.
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Next Generation Welding Helmets Offer Benefits for Operator Comfort and Productivity

Having the best possible helmet for the job can reduce workplace injuries and discomfort — and allows an operator to weld for longer.
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Advantages of Cored Wire in Submerged Arc Welding Applications

Understanding the important roles of the flux and wires can help companies realize the full potential of the submerged arc welding (SAW) process.
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Improving Productivity in Submerged Arc Welding Applications

By increasing travel speeds, reducing weld passes and minimizing arc-off activities, it is possible to improve productivity in the submerged arc welding (SAW) process. Joint design, polarity, torch configuration and flux/wire selection also play a critical role in helping companies get ahead.
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The Latest Welding Technologies Can Save Time and Money

Consider the benefits for productivity, weld quality and cost savings that new welding processes and technologies can provide.
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Remote Control Welding Technology Offers Benefits for Productivity Quality and Safety

Remote control technology provides welding operators with the ability to set welding parameters at the joint, increasing safety by reducing trips to and from the power source, and increasing arc-on time for greater productivity. This technology also helps improve quality by eliminating the need to settle for less-than-optimal settings.
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Wireless Foot Controls Can Benefit Productivity, Quality in TIG Welding

Wireless foot pedals can help improve operator comfort when TIG welding, leading to better quality and productivity. The lack of control cords also reduces clutter on the shop floor for greater safety.
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Marine Hardware Manufacturer Reduces Welding Rework on Anodized Aluminum

G.G. Schmitt & Sons saves time and money with Dynasty® 400 TIG welders, cutting hours of rework on some parts.
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Jimmy Shine Builds on Southern California Hot Rod Tradition

Jimmy Shine is a talented fabricator and hot rodder who relies on Miller equipment to get the job done.
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Georgia Machine Shop Triples Deposition Rate with Submerged Arc System and Metal-Cored Wire

Seeking greater productivity and efficiency, especially on larger weld build-up jobs that could take days or even weeks to complete, Capital City Machine Shop knew it needed a new submerged arc welding (SAW) solution. Capital City’s investment in two SubArc AC/DC 1000 Digital welding power sources, coupled with a switch to Hobart® metal-cored wire, resulted in productivity increases of 240 percent...
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PipeWorx 400 Welding System Improves Manufacturer’s Productivity 50 Percent

A switch to Regulated Metal Deposition (RMD®) helped Sigma Thermal increase productivity while maintaining high weld quality.
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Out Back Aluminum Welding Relies on Versatility of Miller Dynasty 280 DX

Welding is a family passion for Garry and Darryll Euler. Garry remembers learning the trade from his father when he was just 13. Now, Garry runs Out Back Aluminum Welding with his son, Darryll.
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Truck Equipment Manufacturer Improves Employee Comfort and Performance with Powered Air Purifying Respirators

A change to Miller® Powered Air Purifying Respirators helped increase comfort and productivity for Reading Truck Body employees.
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Chandler Equipment Gains Unexpected Benefits from Fume Extractors, Years After Installation

Arkansas-based Chandler Equipment continues to reduce maintenance time and costs with its FILTAIR® centralized fume extractions systems from Miller. Two and a half years have passed since investing in the systems and the company still hasn't needed to change the filters — plus they continue to experience significant fume reduction. 
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Motorsports Welding and Racing Guide

Get tips for choosing the best welding products for race car and motorsports repair and fabrication.
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TIG Welding Chromoly Steel? 5 Tips to Improve Results

TIG welding chromoly requires attention to heat input and best practices for material cleaning as well as choosing consumables.
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How to Drive Improvement with an Existing Welding Power Source Fleet

Utilizing external weld monitoring solutions allows companies to gain insight into quality and productivity metrics on any brand of power source, old or new, so they can drive continuous improvements in their welding operation.
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Guide to Welding Automation

From proper robotic weld cell design to choosing the right gun, many factors play a role in optimizing a robotic welding system.
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Reducing Risk When Investing in Welding Automation: Five Steps to Success

Welding automation can provide companies with competitive advantages by making them more productive and by generating higher weld quality. The technology can also improve their profitability. To gain the best success and reduce the risk in the investment, it’s important to follow some best practices when implementing a robotic welding system.
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The Right Filter Makes a Difference in Weld Fume Management

Choosing the appropriate filter media can help increase productivity and profitability by lowering downtime, improving airflow and reducing filter replacement costs.
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Submerged Arc Welding Tractor Delivers Productivity Benefits

Submerged arc welding delivers benefits for productivity, weld quality and operator comfort. Pairing the process with a SAW tractor can enhance those results.
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What Are the Biggest Challenges of Pipeline Welding?

Hear from pipeline welders about the issues they face on the right-of-way and what equipment helps them be more productive.
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What Is Welding Arc-on Time and Are You Overestimating It?

Average arc-on time in most welding operations is 10%. Get five tips to increase arc-on time in MIG and advanced MIG welding.
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4 Questions About Welding Codes and Qualifying Wire Processes for the Jobsite

Using more productive welding processes can greatly improve efficiency. Learn how easy it is to gain better results.
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How Can Data Increase Arc-On Time in a Welding Operation?

Manufacturers can boost throughput, reduce downtime and ensure quality with advanced welding information management systems.
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Debunking 5 Common Myths About Using Suitcase Wire Feeders on the Jobsite

From poor feeding capability to questions about durability, we’re debunking common misconceptions about suitcase wire feeders.
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What Are Stickout, Electrode Extension and Contact-Tip-To-Work Distance?

Stickout and electrode extension are often used interchangeably. Learn more about the difference and how it impacts weld quality.
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Are Inefficiencies in the Weld Cell Affecting Your Manufacturing Process?

Common manufacturing myths about grinding, arc-on time and spatter may be holding you back from making the right changes.
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5 Tips to Determine the True Cost of Field Welding

Identifying common hidden costs in your field welding operation can help keep your project on time and on budget.
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6 Tips to Improve Welding Productivity on Construction Jobsites

Using more efficient welding processes and technologies can help contractors complete jobs faster and compete for more bids.
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Frequently Asked Questions About GFCI Tripping Issues on Welder/Generators

Is frequent GFCI tripping on your welder/generator causing troubleshooting headaches? Get tips to help resolve these issues.
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Engine-Driven Welder/Generators with Dual-Operator Capabilities Save Space and Fuel

A diesel engine-driven welder/generator with dual-operator capabilities is one tool that offers the versatility to help accomplish what you need to get done in today’s working environment.
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Reduce Weld Fume Exposure by Choosing the Right Option

Protecting employees against weld fumes is critical to providing a safe working environment. Choosing the right weld fume management solutions can also have a positive impact on the bottom line through improved productivity.
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Optimize Robotic Welding Cells by Reducing Secondary Circuit Wear

Learn more about robotic welding cell best practices — and secondary circuit technology — that keep operations optimized.
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An All-In-One Welder/Generator for Powering Jobsite Tools

To meet any jobsite demand, contractors and service truck operators need a welder/generator to power tools and save space.
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Electronic Fuel Injection Technology Improves Efficiency of Engine-Driven Welding Power Sources

Investing in an engine-driven welding power source with technology advancements can dramatically increase the return on investment, resulting in upgrades that pay for themselves in a short time.
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How to Avoid Work Truck Downtime Caused by DPF Regeneration

Less frequent engine regeneration helps you reduce downtime and keep working — saving time and money on your work truck.
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Cleaning Up Your Work Truck Can Impact the Bottom Line

There are many reasons that fleet managers and technicians should keep a work truck clean. Wear and tear, safety, and truck appearance can all impact a company’s bottom line.
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Pro Tips for Understanding TIG Welding Waveforms and Controls

Learn the difference between different waveforms available with inverter machines and how they can help with specific welding tasks.
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What Gas Should You Use for MIG Welding in DIY Applications?

Whether you’re welding mild steel, aluminum or stainless, choosing the right shielding gas is important to getting good results.
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Want To Improve Results When MIG Welding Stainless Steel?

From material prep to choosing a shielding gas, learn how to reduce weld defects and lower costs when welding stainless steel.
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Stroud's Custom Classics: From Cars to Bars

Custom builder Bodie Stroud owns and operates BS Industries in Sun Valley, California. Known for making major changes in a subtle way, Stroud incorporates his vision and style along with modern technologies into a vehicle for a more comfortable ride. His shop specializes in anything pre-1970s — from a stock restoration to the “completely wild” ’63 Ford Galaxy he’ll bring to the SEMA show in the...
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Off-Road Warriors: Camburg Engineering Does it All

Owned and operated by friends Jerry Zaiden and Jason Campbell, Camburg Engineering is a leader in off-road suspension systems and is at the forefront in technology and design. With a shop over 10,000 square feet, Camburg is one of few off-road companies with the manufacturing capabilities to produce their own suspension components in-house as well as build their KINETIK race trucks from the ground...
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A Family Bonded by Welding

Mike Fontes began teaching his daughter Kory Fontes to weld when she was about 10 years old. The family was raising lambs and needed to build a pen. Now the father-daughter duo work side by side teaching the next generation of welders as instructors at Cuesta College, which has a main campus in San Luis Obispo, California, and satellite branches in Paso Robles and Arroyo Grande.
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Submerged Arc Welding Gantry System Makes Crane Fabrication 4 to 5 Times Faster

An automated gantry system with submerged arc welding saves up to 15 hours on each overhead crane build for WF Steel & Crane.
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Osage Ambulances Uses Pulsed MIG Welding To Build Life-Saving Emergency Equipment

The Millermatic® 355 with pulsed MIG capabilities allowed Osage Ambulances to increase productivity and maintain high quality.
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What Is SpeedCore Construction and How Does It Affect Welding?

Learn more about the SpeedCore construction system and how it affects the welding operation, project timelines and results.
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Answers to Frequently Asked Questions About ArcReach® Technology

Learn what ArcReach technology is, how it works and how it helps welders adjust parameters at the weld joint.
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Creating a Safe Welding Environment for (and with) Employees

No two welding operations have the same needs. Equipment, processes and welding operator skill sets vary, as do a company’s safety requirements. Still, employee safety should always be a top priority. Taking the right precautions to protect welding operators can limit negative impacts on production, as well as increase employee acceptance of safety regulations.
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Turning Welding Data into Dollars

A welding information management solution can measure and track performance metrics to improve productivity and quality — making an overall positive impact on your bottom line. Accurate, real-time data collection and analysis can provide a benchmark for measuring the impact of improvements, and the right technology helps you turn that data into dollars.
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Switch to Modified Short-Circuit MIG (RMD®) to Significantly Improve Welding Productivity

Welding plays a significant role in the timely completion of deadline-driven construction projects — both pre-fabrication in the shop and installation on the jobsite. Making the switch from traditional welding processes to a modified short-circuit MIG process such as Regulated Metal Deposition (RMD) from Miller provides improved puddle control and significant productivity gains in many shop and...
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How to Reduce Welding Troubleshooting With Suitcase Wire Feeder Technology

With advancements in wire feeding, welding operations can spend less time and money troubleshooting problems like bird-nesting.
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Game-Changing Welding Technologies Stop You From Wasting Hours Every Day

When welding operators must stop welding to walk to the power source to make adjustments this lost time adds up, totaling significant labor costs that could be better spent on value-added tasks. This productivity loss is especially painful for operations that already struggle to find skilled labor. These stops and starts can also impact weld quality and operator safety.
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Learn Why the CST™ 282 is the Best Portable Stick Welder for the Jobsite

The lightweight CST 282 stick/TIG welder from Miller can help operators complete small repairs and tack welds in any location.
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Solutions for Welding in Hard-to-Reach or Confined Spaces

Learn about technologies that help improve operator safety and comfort, productivity and weld quality when welding in tight or hard-to-reach spaces.
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Shipyards Gain a Competitive Advantage with Point-of-Use Welding Control

Shipyards are being asked to provide lower costs and meet increasing quality requirements while also delivering vessels on tighter schedules. Technology is one solution to help them meet these customer demands. In the shipbuilding welding operation, point-of-use controls can save up to an hour or more every day — per welding operator. The resulting savings translate into a quick return on investme...
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Meet the Demanding Requirements of Welding P91 Pipe With Advanced Wire Processes

Quality is critical in demanding, high-pressure applications that utilize P91 pipe. Contractors must meet stringent quality standards, while also addressing the increasing expectation that projects be completed faster — even as the welding industry faces a shortage of skilled labor. Carefully controlling heat input and choosing the right filler metals is important when welding P91 pipe. In additio...
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Solutions for Gaining Production Efficiency in Pipe Welding

Evolving technologies provide opportunities to increase productivity and maximize efficiency in pipe welding operations. These solutions include more productive advanced welding processes, filler metals formulated to better meet specific needs and welding equipment designed for ease of use and improved productivity.
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Accessing the Advantages of Remote Control Welding Technology

Efficiency, safety and profitability are important to any company, but especially to a welding operation. In addition to general best practices and welding operator training, there are equipment advancements that can help meet quality and production goals, while also helping keep welding operators safer on the job. Remote control welding technology is one of those advancements.
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Investing in Advanced Welding Technologies Can Boost Productivity and Efficiency

There are advanced welding technologies that can improve productivity, quality and safety, all while offering simple setup and ease of use for operators. Some of the advanced features available include point-of-use control, push-button welding parameter adjustment up to 200 feet away from the power source, and advanced welding processes that make it easier for operators to achieve code-quality...
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Ability to Send Welding Parameter Commands through the Weld Cable Eliminates Costly Control Cables, Wasted Time in Construction, Shipbuilding

New ArcReach welding technology sends voltage setting commands through the weld cable and eliminates the need for an extra control cable.
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Apex Steel Saves up to Two Hours Per Welder Every Day With Remote Control Technology

Structural steel contractor improves productivity and jobsite safety with Miller® ArcReach® technology.
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Aluminum Jet Boat Manufacturer Turns to Pulsed MIG to Keep Boat Production at Full Throttle

Smoky Mountain Jet Boats is known as a top-line manufacturer of aluminum jet boats that thrill riders in water as shallow as 4 inches. The boats are made to Coast Guard specs but wouldn't be profitable or even possible without Pulsed MIG welding.
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Shipbuilder Improves Quality Productivity with TIG Welders

Louisiana-based shipbuilder relies on the Dynasty® 400 TIG welders to meet customer deadlines and quality demands.
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Lean Manufacturing Techniques Produce Fat Returns for Todd Pacific Shipyards

As part of company's effort to adopt "5s" lean manufacturing principles, Todd Pacific Shipyard took stock of its welding technology and traded older, larger, and inefficient welding equipment for compact, efficient new inverters and wire feeders from Miller Electric Mfg. Co. As a result, it has saved space, energy and rework time.
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How to Choose the Right Aluminum Filler Metal

Learn how to choose between 4043, 5356 and 4943 aluminum filler metals to ensure quality welds in your operation.

How to Change Nozzle, Tip, Diffuser, and Liner with Set Screw for MDX™ MIG Guns

Follow some simple step-by-step instructions to change AccuLock™ consumables on MDX™ MIG guns and gain an optimal wire feeding path.

How to Reinstall a Trimmed Liner for MDX™ MIG Guns with Set Screw Power Pin Cap

When the power pin cap is removed from a MDX™ MIG gun, the liner can retract and appear too short to lock into place. Learn how to reinstall the liner.

How to Replace Your MDX™ MIG Gun’s Handle, Switch and Neck

Learn how to replace the handle, switch or neck on your MDX-100 or MDX-250 MIG gun.

How to Change Consumables on Your MDX™ MIG Gun

Learn how to change the nozzle, contact tip, gas diffuser or liner on your MDX-100 or MDX-250 MIG gun.

How to Reinstall a Trimmed Liner in Your MDX™ MIG Gun

Learn how to reinstall a trimmed liner in your MDX-100 or MDX-250 MIG gun.

Syncrowave® TIG Welders: General Setup Steps

See every step needed to unbox your new Syncrowave TIG welding power source, finalize its assembly and get it ready to power on.

Syncrowave® TIG Welders: Set Processes and Parameters

See every step needed to set processes and parameters on your new Syncrowave TIG welding power source — so you can get welding!

Syncrowave® 300 and 400 TIG Welding Power Sources

Outdated equipment holds your operation back. Get current with Miller® Syncrowave® 300 and 400 TIG welding power sources!

Welding Aluminum With the Dynasty 280 DX Multiprocess Welder

When welding aluminum, follow these tips to set up your Dynasty 280 DX Multiprocess using an ArcReach SuitCase 12 feeder.

Miller Dynasty TIG Welding Power Sources: No Compromises

Miller Dynasty TIG welding power sources have versatile operating parameters for strong, precise, beautiful welds.

Get Current: New Syncrowave® TIG Welding Power Sources

Get current with a new Miller® Syncrowave® machine. Reduce training time and expenses; get more productivity and better welds.

Dedicated Aluminum Welding Systems Minimize Quality Issues

A dedicated aluminum welder, like a Millermatic 350P Aluminum or AlumaFeed can reduce quality risks, and reduce cleanup.

Selecting the Right Gun for Aluminum Welding

Guns designed specifically for aluminum welding are capable of feeding the soft wire, while also minimizing wire-feeding problems such as bird-nesting.

Adjusting AC Frequency to TIG Weld an Aluminum Cylinder Sleeve

Chris talks about welding dissimilar thicknesses of aluminum with the help of the Dynasty 350 and the adjustable AC frequency controls.

PAR Racing Engines Repairs Engine Block with Dynasty 350 TIG Welder

Miller's Andy Weyenberg and Scott Duggins, PAR Racing Engines, repair an engine block and recommend Dynasty 350 settings for aluminum welding.

Chris Razor Discusses Advanced AC TIG Welding Controls on Aluminum

Chris of Hi-Tech Welding shows advanced AC controls for welding aluminum, including independent amperage control, balance and frequency.

Cotati Speed Shop - Miller Use Diversion™ 180 to Create Aluminum Air Pan for '48 F1 Ford Pickup

Miller product manager John Swartz shares TIG welding techniques as he works on an aluminum air pan from Santa Rosa, Calif.-based Cotati Speed Shop.

Welding in Tight Spaces on ’32 Euro Coupe using Miller Weld-Mask and Diversion 180

Hollywood Hot Rods fabricator Sean welds in tight spaces on a ’32 Euro Coupe. For the project, he relied on the Diversion 180 TIG welder.

Dynasty 280 and Weldcraft Torch Provide Versatility for Aluminum Boat Repairs

Out Back Aluminum Welding relies on the Dynasty 280 DX TIG/Stick welder to gain flexibility and portability for TIG welding on boats — in the shop or at the marina.

Benefits of frequency adjustment on aluminum using the Miller Dynasty 200 DX TIG welder

Miller Marketing Manager John and Pure Vision fabricator Aaron Cranford discuss modifications to the radiator in the Pure Vision TT Camaro.

Miller Multimatic 215 MIG (GMAW) Welding Aluminum Setup

Watch for step-by-step instructions on how to set up the Miller® Multimatic™ 215 for MIG (GMAW) welding aluminum.

Applications for AC Frequency Adjustments

Learn when to use a low frequency setting versus when to use a high frequency setting.

Proper Cleaning Techniques Tied with Balance Control

Miller welding engineer explains how balance control can be adjusted based on the cleaning prior to welding. Having a clean surface allows you to increase your balance control.

Pulsing with TIG

Miller Welding Engineer Zack Erndt explains the benefits of using pulse when TIG welding and talks about applications where low and high pulses per second can be used.

Postflow when TIG Welding

Learn about the value of postflow and what to look for if postflow is not set properly. Without proper settings the tungsten and even the weld could become contaminated.

Miller Multimatic 215 Setup for Stick Welding

Watch for step-by-step instructions on how to set up your Miller® Multimatic™ 215 for stick welding.

Miller Multimatic 215 Lift-Arc TIG (GTAW) Welding Setup

Watch for step-by-step instructions on how to set up the Miller® Multimatic™ 215 in Lift-Arc TIG (GTAW) welding mode.

Miller Multimatic 215 Multiprocess Welder Setup

Watch for step-by-step instructions for setting up and operating your Multimatic 215, and suggestions for correct gas and consumable usage.

Miller Multimatic 215 Flux-Cored (FCAW) Welding Setup

Watch for step-by-step instructions on how to set up the Miller® Multimatic™ 215 for flux-cored (FCAW) welding.

Miller Multimatic 215 TIG (GTAW) Lift-Arc Remote Setup

Watch for step-by-step instructions on how to set up the Miller® Multimatic™ 215 for Lift-Arc TIG (GTAW) using remote.

Miller Multimatic 215 Spoolgun Calibration Procedure

Watch for step-by-step instructions on how to complete the Multimatic™ 215 spoolgun calibration procedure.

DIY Welding Project: Roll Cage Clamp System

Follow these step-by-step instructions to create custom locking pliers using your multiprocess welder.

How to MIG Weld Aluminum with the Multimatic 220 AC/DC

Setting up you Multimatic 220 AC/DC to MIG weld aluminum is easy. Follow these steps to get started.

G.G. Schmitt Reduces Rework by 10% With Dynasty Welders

With the marine industry booming, see how hardware manufacturer G.G. Schmitt & Sons reduces rework and cuts welding time.

Miller Preheating Technology for Roll-Welded Pipe Increases Quality, Productivity and Safety

Gaining consistency in preheating rolled pipe, or flat plate or seam welds, without the hassle and hazards of open flames, increases safety and efficiency.

Dynasty® 210 Product Overview

Miller’s Dynasty® 210 is a portable AC/DC TIG and stick capable power source rated for ¼” thick material.

Maxstar® 161 Product Overview

The Maxstar® 161 offers three models, all with a digital meter and each weighing only 13 pounds!

TIG Welding Aluminum for Beginners Part 1: Positioning

Learn some best practices for hand and torch placement — key to puddle control — when TIG welding aluminum.

TIG Welding Aluminum for Beginners Part 2: Establish the Puddle

Learn how to start your arc, establish the weld puddle, and manage your current when TIG welding aluminum.

TIG Welding Aluminum for Beginners Part 3: Adding Filler Metal

Andy Weyenberg, aftermarket and performance manager for Miller, demonstrates the dab-and-move technique for TIG welding.

TIG Welding Aluminum for Beginners Part 4: Setting Parameters

When TIG welding aluminum, learn how weld settings like balance and frequency can make a big difference in the final weld.

Miller TIG Welders Deliver Best Arc for Manufacturer

Fort Defiance Industries manufactures critical medical devices for the U.S. military with the help of Miller Dynasty® machines.

Fort Defiance Industries Relies on Miller Dynasty Machines

The Miller® Dynasty® machines used by Fort Defiance Industries provide capabilities for a dynamic manufacturing environment.

K-zell Metals and the AlumaFeed Synergic Aluminum Welding System

K-zell Metals relies on Miller's AlumaFeed Synergic System for welding aluminum components. Benefits are excellent arc starts and aesthetics.

TIG Welding Aluminum Tanks with the Miller Syncrowave 210

Andy Weyenberg and Joe Constance of Joes Racing Products use the Syncrowave 210 TIG welder to fabricate custom aluminum tanks.

Rick's Restoration Relies on Miller Pro-Set Feature

Tyler Dale and the rest of the team at Rick’s Restoration utilizes the Pro-Set™ feature on their Miller® TIG welders in the shop.

Jetline Seam Trackers Simplify Welding and Improve Quality

See the Jetline® Tactile Seam Tracker system in action as it consistently positions the weld head for optimal arc performance.

H&W Pacific Emergency Vehicle Group Updates Shop with Versatile Welding Equipment from Miller

H&W decided an update in welding equipment was needed to keep up with growing demand for aluminum and stainless materials.

H&W Operators Find Invision Welding System User Friendly with Better Arc Control

H&W Pacific Emergency Vehicle Group uses Invision 352 MPa Plus to increase productivity thanks to more control and longer leads.

Miller Millermatic MIG Welders - Aluminum Welding

Aluminum welding. How to MIG weld on aluminum with a Millermatic and a Spoolgun. set up and weld techniques are covered.

Smoky Mountain Jet Boat Built with Pulsed MIG Technology

Jet Boats is building aluminum in the mountain woods, using Miller's latest Pulsed MIG technology to ride the wave of boat orders.

Improve Aluminum Wire Feeding With XR-AlumaFeed® System

Inconsistent wire feeding can cause birdnesting and other problems that result in time lost to liner changes and troubleshooting.

Lighter Gun Improves Productivity in Aluminum Welding

The XR-Aluma-Pro™ gun is lighter than previous designs, to reduce fatigue and improve operator output in aluminum welding.

Miller Spoolmate 100 MIG Gun for Welding Aluminum

The Spoolmate 100 is the economical and versatile solution for welding aluminum with your Millermatic, handling 4043 alloy and 0.30 to 0.35 aluminum wire.

Using Balance Control for Controlling Oxides vs Cleaning Material

Miller Weld Technician explains the difference between using the balance control for the removal of oxides vs using proper materials.

Tackle More Projects With Spectrum® Plasma Cutters

The Spectrum 625 X-TREME™ plasma cutter gives Jason Wilson, owner of Dane Fabrication, the flexibility to tackle more projects.

How to Create a Money Clip with the Miller Dynasty 210 DX TIG Welder

Josh Welton of Brown Dog Welding demonstrates how to create a money clip using the Dynasty® 210 DX TIG welder.

Using the Miller Pulse Feature

Pulsing allows you to alternate between a high and low current to control heat input into a part on a given material. The main benefit of pulsing is control.

Setup and Use of Miller Pulsing Control Features

Learn how to set up and use the Miller pulse feature as well as how making minor adjustments will allow you to better create distinct ripple patterns.

What’s Next: Faster Multiprocess Welding With Josh Welton

Brown Dog Welding owner Josh Welton quickly switches between welding processes with his Miller® MDX™-250 EZ-Select™ MIG Gun.

Plasma Cutting FAQ with Metal Artist Stephen Christena

Metal Artist Stephen Christena of Midwest Metalworks answers some commonly asked plasma cutting questions.

What’s Next: Building Off-Road Vehicles With The MDX™-100

UTV Wolfpack creates the off-road racing industry’s most innovative suspension systems and cages with the MDX™-100 MIG gun.

What’s Next: RMD Garage Shows Off MDX™-250 Gun

Next-level ergonomic features are why Eddie Luv of RMD Garage calls the Miller™ MDX-250 MIG gun his “new baby.”

TIG Welding Punisher Trailer Hitch Cover with Miller Syncrowave 210

Josh Welton of Brown Dog Welding creates a trailer hitch cover. Watch as he uses the Spectrum® 375 X-TREME™ to cut out the design and then TIG welds it together.

Manufacturer Welds Mill Finish and Anodized Aluminum Parts

As the marine industry moves to more custom designs, G.G. Schmitt & Sons relies on Dynasty® welders to fabricate innovative parts.

Miller Service Important to Marine Hardware Manufacturer

Fabrication for the marine industry demands high quality, and welding equipment is a key factor in producing the best results.

Marine Manufacturer Cuts Hours of Rework on Aluminum Welds

Welding anodized aluminum requires a skilled welder and attention to detail. See how G.G. Schmitt & Sons reduces rework.

How to Reduce Scrap on Bright Dip Anodized Aluminum

Manufacturer G.G. Schmitt welds many types of aluminum, including bright dip anodized. See how Dynasty® welders help reduce rework

G.G. Schmitt Completes Welds Faster With Dynasty Welders

A switch to Dynasty® welders helped marine hardware manufacturer G.G. Schmitt & Sons improve productivity in the welding operation.

Millermatic 350P Aluminum Set Up and Operation

An in-depth look at the settings and capabilities of the Millermatic 350P, an all-in-one MIG welding system designed specifically for aluminum.

Setting Up Your Multimatic® 235 to MIG Weld Aluminum

Learn how to set up your new Multimatic 235 welding power source to MIG weld aluminum with a spool gun.

Multimatic® 235: Access Service Menu and Calibrate Spool Gun

Learn to access the service menu on your Multimatic® 235 welding power source and use it to calibrate the motor on your spool gun.

Syncrowave® 210 Product Overview

The easy-to-use Syncrowave® 210 provides legacy arc performance that allows you to expand your capabilities with an all-in-one package.

Fabricator Reduces Power Draw by 25-30% with Miller Welding Inverters

OMF Performance Products reduced power draw substantially by switching from an old transformer-based welder to two inverter-based welders.

DIY Welding Project: Planter and Flower Vase

A DIY planter and flower vase will add character to any home. Get the instructions on how to create this cool welding project.

How to Build an End Table with the Miller Multimatic 215

Zach MacMullen uses the Multimatic™ 215 to weld up this end table. See how he quickly tack welds the project together.

Welding Dragonfly Yard Art Project with Miller Multimatic 215

See Josh Welton of Brown Dog Welding weld the steel structure of the dragonfly and then brazes copper on to the yard art using a TIG torch.

Improve Out-of-Position Welding Results With Pulsed MIG

Out-of-position welds can be challenging. Learn more about the benefits of switching to pulsed MIG for welding out of position.

Garage Layout Ideas for Setting Up Your Welding Space

Want to convert your space into a welding shop, but not sure where to begin? Get some inspiration from a pro.

Hollywood Hot Rods Loves Miller Weld-Mask for Welding in Real World Applications

Troy Ladd and team at Hollywood Hot Rods rely on the new Miller® Weld-Mask™ auto-darkening goggles for welding in tight spaces.

TIG Welding Aluminum: AC Balance Control

Proper AC Balance settings are critical to weld performance, quality, and tungsten life when TIG Welding.

MIG Welding Water Bucket Holders for Horse Barn with Millermatic 211

Joel Ort of Miller Electric Mfg. Co. creates water bucket holders to mount in his horse barn using the Millermatic 211 MIG welder.

At Pure Vision, the Cars and People Are Anything but Ordinary

Pure Vision has become a world-renowned street machine fabrication shop, known for a very signature concept and build style.

Overview of Pure Vision's Twin Turbo Camaro Build

Located in Simi Valley, Calif., Pure Vision has become a world-renowned street machine fabrication shop, known for a very signature concept and build style that can be described as simple, straightforward and well-detailed. In this video, shop owner Steve Strope shares a quick overview of the Twin Turbo Camaro build that the shop is currently working on.

Troubleshooting Aluminum Welding Problems

Learn how to solve for common aluminum welding problems in your operation, such as porosity and smut.

TIG Welding Aluminum: AC Frequency Control

Learn how to adjust AC frequency to gain greater arc puddle control when TIG welding aluminum on Miller Maxstar or Dynasty TIG welders .

Bollinger Shipyards and Advanced Pulsed MIG Welding on Aluminum

Bollinger Shipyards improves productivity and simplifies aluminum welding on patrol boats with Miller's advanced AlumaFeed™ Synergic Aluminum.

Miller's Aluminum Welding System helps Metal Shark Aluminum Boats

Metal Shark increased efficiency, doubled production, and cut welding time in half by using Millermatic 350P pulsed MIG welders.

Multimatic® 235 Welder Helps Keep Wisconsin Village Running

The Wisconsin village of Combined Locks has one maintenance mechanic. His Multimatic 235 helps keep the village running.

Multimatic 235 Ideal for Welding and Fabrication Shops

See why the Multimatic 235 multiprocess welder is the one machine that handles most welding jobs at M-Fab and Welding LLC.

Hot Rods by Dean Loves the Miller Wireless Foot Control

Jerry Miller, fabricator at Hot Rods by Dean, recommends the Miller® Wireless Foot Control when TIG Welding.

Short Arc to Pulsed MIG: Changing Processes With a Tap

Watch Roadster Shop fabricator Kellen Bain weld a spec Camaro chassis with the Multimatic® 255 multiprocess welder.

Using the Miller Balance Control Feature

Miller Weld Technician Mark Kadlec demonstrates the Miller balance control feature and provides instructions for proper use.

Fabricator & Metal Artist Josh Welton Reviews Miller Dynasty 280 DX TIG Welder

In this video, professional fabricator and owner of Brown Dog Welding Josh Welton reviews the Miller Dynasty 280 DX TIG welder w/ wireless foot pedal. Compared to similarly sized machines, the Dynasty 280 delivers more power and provides the ability to weld metal up to 3/8-inch thick — yet is lighter, more portable and uses less energy than machines of similar output capabilities. Weighing in at...

Dirty Power? Discover Auto-Line Power Management Technology

Maintaining arc consistency with dirty input power can be difficult. Auto-Line™ power management technology alleviates this issue.

Create Your Own Mid-Century Wall Art with These Simple Steps

Miller partners and friends Max Grundy (of Max Grundy Design) and Josh Welton (of Brown Dog Welding) create a mid-century art piece.

Why the Millermatic® 211 MIG Welder Is a Cut Above the Rest

Jason Wilson, owner of Dane Fabrication, trusts his Millermatic 211 to make his custom iron and woodwork designs come to life.

Miller Multimatic 255: Built for Chassis Fabrication

The master fabricators at Roadster Shop rely on the Multimatic® 255 for MIG and TIG welding their in-demand chassis.

Avoid Common TIG Welding Problems with a Dynasty TIG Welder

John Marcella of Marcella Manifolds discusses how he addresses weld aesthetics with the advanced capabilities of the Dynasty 350 AC/DC TIG inverter from Miller.

Welding Process Change Makes Manufacturer More Competitive

A welding process conversion to Regulated Metal Deposition (RMD®) helps Sigma Thermal stay ahead of the competition.

How to Build a Car Bumper Using a TIG Welder

Watch motorsports professional Craig Curione build a bumper for his Can-Am car in his shop using the Syncrowave® 210 TIG welder.

NASCAR Champion Bobby Allison Welds It All with Multimatic 215

NASCAR Hall of Famer Bobby Allison knows what it takes to compete — and win. That’s why he uses Miller’s Multimatic™ 215 multiprocess welder.

NASCAR Champ Bobby Allison Shares His Favorite Bristol Memory

NASCAR Hall of Famer Bobby Allison shares his favorite memory from Bristol Motor Speedway and driving for Junior Johnson.

Do It All With the Multimatic® 220 AC/DC Multiprocess Welder

Josh Welton, owner of Brown Dog Welding, explains the reasons why he loves his Miller® Multimatic 220 AC/DC multiprocess welder.

Notching Frame for Suspension Clearance using Miller Dynasty 350 DX TIG welder and Weld-Mask

Hollywood Hot Rods fabricator Sean Ramáge completes a frame repair to provide more suspension clearance.

See How Kindig-It Design Uses Workhorse Millermatic 211

The Millermatic® 211 is known as the shop workhorse at Kindig-it because it’s reliable and powerful — making it perfect for welding jobs both big and small.

Kindig-It Design Uses Multimatic 215 to Do It All

To turn out custom auto designs and restorations for the show Bitchin’ Rides, the crew from Kindig-It Design needs welding equipment that does it all.

Bentley Garner Shares Tips for Successfully Welding Chromoly Tube

Bentley Garner gives step-by-step instructions and tips on chromoly tube welding, using the Multimatic™ 215 multiprocess welder.

TIG Welder is Critical to Car Restoration for Ray Evernham

Ray Evernham, a NASCAR Hall of Fame crew chief and car owner, has a long career in racing. Through the years, he’s always relied on Miller® welders.

NASCAR Hall of Famer Ray Evernham Relies on Miller Welders

NASCAR Hall of Fame crew chief and car owner Ray Evernham has been in racing a long time, and he’s worked with the best — Miller® welders have always been part of his work.

TIG Welding Custom Cars at Detroit Speed

Detroit Speed and Engineering builds custom cars for customers all over the world. To fabricate car panels, Detroit Speed relies on the Syncrowave® 210 TIG welder.

TIG Welding Sheet Metal Techniques With Bodie Stroud

Learn some techniques for TIG welding sheet metal, which requires properly controlling heat and preventing warpage.

Choosing a TIG Welder — Learn More About the Syncrowave 210

If you’re in the market for a new TIG welder, an inverter-based Syncrowave® 210 provides AC TIG for welding aluminum and a spool gun accessory.

Use the Welders that Hendrick Motorsports Relies On

Hendrick Motorsports has built a winning tradition — earning a record 12 championships in NASCAR since 1984.

Creating Something from Nothing is the Power of Welding for Bentley Garner

Bentley Garner loves to build and create just about anything. This welder/fabricator out of Salt Lake City uses Miller machines for all of his welding needs.

NASCAR Champ Bobby Allison Recreates His Dodge Charger

NASCAR Hall of Famer Allison is recreating the iconic Dodge Charger he raced in 1969 and 1970, including another 500-mile victory in 1970.

How to Weld Different Metal Thicknesses Together

Peter Torres from BS Industries shows how to weld steel of various thicknesses together using his Miller® TIG welder.

Meet the Kindig-It Design Crew from Bitchin’ Rides

Turning autos into custom works of art is Kindig-It Design’s specialty. They rely on Miller® welding equipment, so they can build most anything.

Plasma Cutters Deliver Speed and Performance for Evernham

Miller Spectrum® plasma cutters deliver a small heat zone, a clean cut and reduced cleanup — saving time and money in Ray Evernham's shop.

Get Amazing Arc Control and Easy Process Changeover with the Multimatic 215

Bentley Garner loves the Multimatic™ 215 multiprocess welder. This portable machine can switch from MIG, to TIG, to stick in a split, saving time and space.

Swap Your Grinder for a Miller Spectrum X-TREME Plasma Cutter to Save Time

Bentley Garner uses the Spectrum® 625 X-Treme™ Plasma Cutter for Gouging in his shop. Garner finds that using his plasma cutter is the more efficient solution.

Win a VIP Race Experience and Hendrick Motorsports Tour

The grand prize winner will receive an exclusive, behind-the-scenes tour of Hendrick Motorsports, as well as suite tickets and pit passes to the 2018 Foods City 500 NASCAR race.

TIG Welding in the Field Requires Portability Flexibility

Motorsports professional Craig Curione uses Syncrowave® 210 TIG to build and restore side-by-side race cars because it offers lightweight portability.

Kindig-It Design Modifies a Hummer Bumper with the Millermatic 211

Watch this video to see the Kindig-It Design team modify a Hummer H2 bumper using a Millermatic® 211.

Welding Helmet Increases Visibility with X-Mode Technology

Rick’s Restoration does a lot of work outside, which is why they depend on X-Mode™ technology in their Miller® welding helmets.

ClearLight Lens Technology Provides ‘Crystal-Clear View'

Jerry Zaiden, co-owner of Camburg Engineering, tried Miller ClearLight™ Lens Technology. See what he had to say.

Auto-Darkening Helmet Can Help Improve Weld Consistency

Welders can get a better view of their surroundings — which helps improve bead consistency — with an auto-darkening weld helmet.

Arc Academy Makes Welding Accessible, Easy-to-Learn

In a partnership with Miller, Arc Academy offers multiple welding bays with easy-to-use welding machines designed for the hobbyist to semi-pro welder.

Arc Academy Creates Coffee Table Using Miller MIG and TIG Welders

Steve demonstrates how to build a coffee table using a Millermatic 211 Auto-Set MIG welder and Diversion 180 TIG welder.

Bodie Stroud Fine-tunes Arc With Millermatic 252 Welder

Fabricator Bodie Stroud relies on the Millermatic® 252 welder because it’s versatile and easy to adjust.

Importance of Correct Tungsten Preparation

Miller Weld Technician explains the importance of correct tungsten preparation and demonstrates using both a tungsten grinder and traditional shop grinder.

Utility Tractor Hitch Repair Using the Multimatic 215 Multiprocess Welder

Joel Ort of Miller Electric Mfg. Co. uses the Stick welding process to repair a hitch on his utility tractor with the Multimatic™ 215 multiprocess welder.

Chris Razor Discusses Advanced AC Controls, Trianglulated Waveform for TIG Welding

Chris Razor of Hi-Tech Welding discusses independent amperage, balance and frequency settings on his Dynasty 350.

Pure Aluminum Hull Built with Miller Welders: Smoky Mountain Jet Boat Goes for a Ride

Smoky Mountain Jet Boats are assembled using Pulse MIG from Miller welding equipment.

Sportsfield Specialties and Pulsed MIG Welding with the New Millermatic 350P Aluminum

Sportsfield Specialties found solutions to their aluminum welding challenges when it implemented a Pulsed MIG welding process.

Chris Razor of Hi-Tech Welding Discusses TIG Inverters

Listen to the advantages of TIG inverters: increased productivity, greater quality, greater energy efficiency, advanced controls.

Marcella Manifolds & TIG Welding Aluminum Manifolds

Owner of Marcella Manifolds discusses the evolution of GTAW welding, including the advanced AC TIG controls.

ProHeat™ Rolling Inductor Provides Safer Alternative to Preheating Rolled Pipe

Preheating is critical to achieve high weld quality; it eliminates moisture and reduces the opportunity for hydrogen cracking.

Miller's AlumaFeed™ System Excels in Aluminum Shipbuilding

Bollinger Shipyards is able to simplify operation, improve productivity, improve quality, reduce distortion, and reduce bird nesting.

Welding Allows Max Grundy to Make Artistic 2D Visions into 3D Realities

Artist and fabricator Max Grundy creates “retro-futuristic” art, taking themes from a bygone era and placing them into post-apocalyptic scenarios.

Explore more projects with NEW Multimatic 215 multiprocess welder

NEW Multimatic™ 215 provides up to 230 amps of power for MIG! Add an electrode holder or a torch and it’s ready for stick or TIG welding too.

Accessories and Components to Help Solve Your Welding Problems

At Richard Childress Racing, fabricators address many welding challenges — just like you do in your shop or home garage.

Smoky Mounatin Jet Boat Relies on Partnership with Miller and Local Distributor for Solutions

Smoky Mountain Jet Boats builds 100% aluminum watercraft. The company turns to Miller for the latest Pulse MIG welding technology to get the job done.

Tips for Choosing the Right Welder for Your Application

It’s important to consider the input power available, material to be welded, and the prime window in which a specific machine operates best.

Jimmy Shine Builds on Southern California Hot Rod Tradition

With so many high-profile projects in the works, Jimmy Shine needs quality equipment to do a quality job. Shine has relied on Miller equipment since he was 13.

Welding Basics for Beginners

If you are a new or beginner welder, watch this video to learn about the three most common welding processes — MIG, stick and TIG — including the advantages and disadvantages of each, when it’s best to use each and what material can be used.