Aluminium Welding Cyprus — TIG from €85/hour

Q: Why is aluminium harder to weld than steel?

Aluminium has an oxide layer with a melting point of 2050°C, while the metal itself melts at 660°C. Without special preparation and TIG welding on alternating current (AC), this layer doesn't break down and the seam becomes porous and weak. Also, aluminium is highly heat-conductive — preheating is required.

01 / GRADES

Which aluminium grades do we weld

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6061-T6

Structural alloy

The most common structural alloy. Medium strength, excellent weldability. Used for frames, profiles, canopies, trailers. Filler rod 4043.

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6063-T5

Architectural profiles

Extruded profiles, window frames, facade elements. Lower strength than 6061, but easier to process and anodize. Ideal for decorative structures.

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5083-H116

Marine grade

Marine alloy with high corrosion resistance. Boat hulls, T-tops, bimini frames, railings. Stronger than 6061. Filler rod 5356.

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4043

Filler rod

Standard filler rod for 6xxx series (6061, 6063). Contains 5% silicon — reduces cracking and improves flow. Most versatile filler.

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5356

Marine filler

Filler rod for 5xxx series (5083, 5086). Higher strength than 4043, better corrosion resistance. Required for boat hulls and marine structures.

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Cast aluminium

Repair

Cast parts: manifolds, gearbox housings, wheels. Difficult to weld — requires preheating and special filler. I assess if repair is feasible.

02 / APPLICATIONS

What we weld from aluminium

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Boats and Marine

TIG welding of boat hulls, repair of cracks and holes. T-tops, bimini frames, motor mounts, railings, fishing rod holders. I work with 5083 marine alloy — seams stronger than base metal. Service in Larnaca, Limassol, Ayia Napa marinas. I come to the dock with TIG equipment.

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Trailers and Vehicles

Boat trailer repair, cargo trailer welding, ATV and motorcycle trailer frames. Crack repair, reinforcement, custom modifications. I work with 6061 — optimal strength-to-weight ratio. I come to your location with TIG equipment.

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Structures and Profiles

Welding of aluminium profile frames, canopies, pergolas, gates, railings. Facade profiles, window frames, partitions. Decorative structures, sculptures. I work with 6061 and 6063. The seam can be polished or anodized after welding.

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Parts and Repairs

Crack repair, hole filling, reinforcement of parts. Manifolds, housings, flanges, fittings. Rims, bumpers, custom parts. Cast aluminium repair — if technically feasible. Preheating, proper filler selection, post-treatment.

03 / HOW WE WELD

TIG AC aluminium welding process

Surface Preparation

Remove oxide layer with stainless brush or sandpaper. Degrease with acetone. Aluminium has an oxide film with melting point 2050°C (metal itself melts at 660°C) — without removal, the seam will be porous.

Preheating

Thick metal (5mm+) is preheated to 150–200°C. Aluminium conducts heat 4× faster than steel — without preheating, the arc extinguishes and there's no penetration. Thin metal can be welded without preheating.

TIG AC Welding

Alternating current (AC) breaks down the oxide film and provides penetration. Argon gas protects the weld pool. Tungsten electrode 2.4–3.2 mm. Filler rod 4043 or 5356 depending on alloy. Speed — 10–15 cm/min.

Quality Check

Seam without pores, cracks, undercuts. Clean transition to base metal. For critical parts — liquid penetrant inspection. For marine structures — full penetration test.

04 / TECHNOLOGY

Why AC current for aluminium

Aluminium cannot be welded with DC current like steel. It requires alternating current (AC) — this is the fundamental difference between aluminium and steel welding.

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Oxide Film Breakdown

Positive half-cycle of AC breaks down the oxide film (melting point 2050°C) that forms on aluminium surface. Without this, the seam won't penetrate the metal.

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Metal Melting

Negative half-cycle melts the base metal (melting point 660°C) and provides penetration. AC balances between film breakdown and metal melting.

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Argon Shielding

Pure argon protects the weld pool from oxygen. Aluminium is very active — without shielding, the seam will be porous and weak. Argon flow — 8–12 L/min.

OXIDE LAYER

2050°C

ALUMINIUM

660°C

AC FREQUENCY

50–200 Hz

ARGON FLOW

8–12 L/min

CONFIGURATOR

Work out your aluminium welding

The price comes from the seam length and the metal thickness. The diagram shows what each joint type actually means.

SEND THIS CONFIGURATION TO WHATSAPP

Typical configurations and prices

0.2 m × 1 mm · Painted steel · Fillet weld €100

2 m × 3 mm · Painted steel · Fillet weld €100

2 m × 3 mm · Painted steel · Lap joint €100

10.1 m × 6.5 mm · Cast iron · Fillet weld €750

20 m × 12 mm · Painted steel · Fillet weld €800

Why the price here is approximate

What the page works out is an estimate, not a quote. The final figure is always worked out separately, because the same structure in two different places does not cost the same.

How easy the spot is to reach, and whether the van and the gear fit.
What it stands on and bolts to: wall, concrete, roof, soil — the condition of the base changes the job.
Where reinforcement is needed and where it can be done more simply — and come out cheaper.
How fast you need it, and how much preparing the site takes.

This is not factory production, where everything comes out identical, soulless and at the lowest price. Each piece is made for your particular spot. Write to me — we will go through where reinforcement is worth it and where it is not, and I will find an option that suits you.

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06 / ADVANTAGES

Why choose us for aluminium welding

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AC TIG Specialization

I work exclusively with TIG AC — the only correct method for aluminium. DC or semi-auto won't give a quality seam.

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Marine Experience

I weld boats in Larnaca, Limassol, Ayia Napa marinas. I know 5083 alloy and requirements for marine structures.

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Mobile Equipment

TIG welding machine in van. I come to your location with all equipment — no need to transport the part.

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Quality Guarantee

Seam without pores, cracks, undercuts. For critical parts — liquid penetrant inspection. Marine structures — full penetration test.

08 / FAQ

Frequently asked questions

How much does aluminium welding cost in Cyprus?

TIG argon aluminium welding — from €85 per hour. Boat or trailer part repair — from €100. The exact cost depends on volume and complexity. Send photos via WhatsApp — I'll calculate within 1 hour.

Why is aluminium harder to weld than steel?

Aluminium has an oxide layer with melting point 2050°C, while the metal itself melts at 660°C. Without special preparation and TIG welding on alternating current (AC), this layer doesn't break down and the seam becomes porous and weak. Also, aluminium is highly heat-conductive — preheating is required.

Do you repair aluminium boats in Cyprus?

Yes. I work with boats in Larnaca, Limassol marinas and across Cyprus. TIG welding of aluminium hulls, T-tops, bimini frames, motor mounts. I come directly to the dock with equipment.

What aluminium grades do you weld?

Main grades: 6061-T6 and 6063-T5 for profiles and structures, 5083 for marine applications (boats, docks). Filler rod is selected to match the base metal — 4043 or 5356.

Can aluminium be welded with semi-automatic welding?

In theory yes, but in practice the quality will be much worse than TIG. Semi-auto doesn't break down the oxide film as well, the seam is coarser, there are pores. For responsible structures (boats, trailers) — only TIG AC.

How long does boat hull welding take?

Depends on damage size. Small crack (10–20 cm) — 1–2 hours. Large hole or section replacement — 4–8 hours. I assess work volume after photo inspection or on-site visit.

Do you weld cast aluminium?

Yes, but not all castings can be welded. Some alloys crack when heated. I assess the alloy, determine if repair is possible. If yes — preheat to 250–300°C, special filler, slow cooling. Success rate — about 70%.

How to prepare aluminium for welding?

Remove oxide layer with stainless brush or sandpaper. Degrease with acetone. Don't use steel brush — embeds iron particles that cause corrosion. Before welding I additionally clean the joint with acetone.

How strong is the TIG seam on aluminium?

With correct filler selection — the seam is as strong or stronger than the base metal. For 6061 with 4043 filler — seam strength 80–90% of base metal. For 5083 with 5356 filler — seam can be stronger than the base.

Does aluminium need painting after welding?

For most applications — no. Aluminium self-protects with an oxide layer and doesn't rust. For decorative appearance, anodizing (factory process) or powder coating can be done. If the structure will be near the sea — even without painting, aluminium lasts 30+ years.

Aluminium Welding
in Cyprus — boats,
profiles, structures.

Which aluminium grades do we weld