A Pacific Northwest marine fabricator calculated true weld cost on 0.090" 6061-T6 aluminum sheet using IronKit's Weld Cost Calculator. The shop runs a push-pull spool gun with 1.2mm ER4043 wire and 100% argon shielding gas — arriving at $2.50 per linear inch of weld. The key cost driver on thin aluminum is gas consumption: 100% argon at $0.45/cu ft and 30 CFH adds up quickly. The calculator also flagged that at 0.090" wall, burn-through risk increases travel speed requirements, which reduces deposition rate and increases per-inch cost versus thicker plate.
Frequently Asked Questions
Why is aluminum welding more expensive per inch than steel?
Three reasons: (1) 100% argon costs 4× more than 75/25 Ar/CO2; (2) lower travel speed on thin aluminum increases arc time per inch; (3) more setup time — aluminum requires degreasing and oxide removal before every weld. These factors combine to push aluminum cost 2–3× above equivalent steel.
What is deposition efficiency for aluminum MIG?
ER4043 in 1.2mm has roughly 92% deposition efficiency — slightly lower than solid steel wire due to spatter and burn-back. ER5356 runs similar efficiency. The bigger loss on aluminum is the increased stub/waste from spool gun liner drag.
Can I reduce the gas cost for aluminum MIG?
Reducing flow below 28–30 CFH risks porosity — especially at travel speeds above 20 in/min. You can switch to a larger cup with fewer turbulence issues, but the base CFH requirement stays the same. Gas is the dominant cost lever; buying larger cylinders reduces unit cost but doesn't change consumption.
Does IronKit account for burn-through risk in cost calculations?
Yes. IronKit adjusts the productivity factor (arc efficiency) based on material thickness. Below 1/8" aluminum, it applies a reduced travel speed and lower arc-on percentage to reflect the additional care required to avoid burn-through.