Using too small a filler rod can be a problem too.
Tig welding thin aluminium sheet.
Learn why mig pulsed mig tig and pulsed tig are the ideal choices when welding sheet metal.
However welding aluminum presents some challenges from controlling heat input to dealing with the oxide layer.
But using this method also requires some practice and practice advice in order to understand it.
Short circuit transfer mig short arc tig and pulsed tig welding processes provide the most control over the heat to address these challenges.
Using this process enables more than effective work on thin materials as it provides high precision and high quality work.
I used 1 16 1 6m 4043 rod for this outside corner joint in 040 and it worked out ok.
But that is only a guideline.
Tig welding for sheet metal using a tig welders means that one can work on materials of 26 gauge.