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ALL CYPRUS // TIG AC · 6061 · 6063 · 5083 · MARINE
Aluminium Welding
in Cyprus — boats,
profiles, structures.
TIG argon welding of aluminium alloys. Boat hulls, T-tops, trailers, canopies, profiles, gates, railings. Clean seam without pores. On-site service with equipment across the island.
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.
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.
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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.
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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.
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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
05 / PRICES
Aluminium welding cost in Cyprus
TIG AC Welding
€55/hr
TIG welding on AC current
6061, 6063, 5083 grades
Filler rod 4043 or 5356
Argon shielding
Clean seam without pores
Boat/Trailer Repair
from €80
Crack and hole repair
Hull section replacement
T-top, bimini welding
Motor mount reinforcement
Service in marinas
On-Site Service
€20–40
Travel within 30 km — €20
Travel 30–60 km — €30
Travel 60+ km — €40
TIG equipment in van
Welding at your location
Final cost depends on metal thickness, seam length, accessibility, and alloy. Send photos in WhatsApp — I'll calculate within 1 hour.
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.
TIG argon aluminium welding — from €55 per hour. Boat or trailer part repair — from €80. 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.
