What the price depends on
Mostly metal thickness and weld length. Thin sheet needs careful work at low current, while a thick part has to be preheated. Castings (housings, covers, factory brackets) are harder than sheet or extrusions, because they can be porous and soaked with oil. It also matters whether the part can come off and go to a workshop, or has to be welded on site. Labour rates are in the table below.
| Service | Price |
|---|---|
| Aluminium welding | 280–400 zł/h |
Indicative prices. Ranges for a typical scope. Fixings included, materials separate. Minimum order 300 zł.
Filler wire or rod, shielding gas, new parts to replace corroded ones and transport are paid separately, as agreed in the handyman’s offer.
Price ranges and offers from tradespeople: wall filling and skimming in Warsaw.
Why aluminium is different
Aluminium always carries an oxide film on its surface. That film melts at a far higher temperature than the metal underneath, so it’s removed before welding and broken up by the arc during it. Aluminium also conducts heat well and doesn’t change colour before it melts, which is why an inexperienced welder can easily burn straight through.
TIG on AC is the usual method: argon, a tungsten electrode and a filler rod. It’s used for thin sheet, small parts and neat visible welds. For thick material and long runs, pulsed MIG makes more sense, with the wire fed automatically. The filler is matched to the alloy, typically AlSi5 or AlMg5.
Not everything made of aluminium is worth welding. With heat-treated alloys the metal next to the weld ends up noticeably weaker. So load-bearing parts (ladder treads and stiles, wheel rims, suspension and steering parts) are normally replaced, not welded. A handyman is entitled to turn that kind of job down, and that’s fair.
Safety first
A welding arc gives off strong UV radiation, so never look at it without a mask, not even for a second. Welding also produces fumes and gases, which means indoor work needs good ventilation, and nothing flammable should be nearby. Most important of all: containers that held fuel, oil or solvent are never welded without proper preparation. Vapour inside can ignite from a spark even when the tank looks empty. If anything like that is part of the job, say so up front.
How the job is done
- The handyman inspects the part, works out whether it’s sheet, extrusion or casting, and decides if welding makes sense.
- If possible the part comes off, and paint, oil and dirt are cleaned from the weld area.
- The crack is opened up, and small holes are often drilled at each end so it can’t run further.
- Right before welding, the area is degreased and gone over with a stainless steel brush.
- Thick parts are preheated, then welded.
- The weld is cleaned up, the part refitted and checked under load.
Common mistakes
- Welding over paint and oil, which leaves the weld porous like a sponge.
- Cleaning with a brush that has been used on steel: iron particles contaminate the weld.
- Grabbing whatever filler is to hand without checking the alloy.
- Welding a crack without stop holes at the ends, so a month later it carries on past the weld.
- Trying to weld a load-bearing part that really needs replacing.
- Welding an anodised part in a visible spot, then finding the coating has burnt off around the weld and has to be redone separately.
What to prepare
- A close-up photo of the crack, with a ruler or coin next to it for scale.
- A photo of the whole part and a note on what it is and what load it carries.
- The alloy marking, if it’s on the part or in the paperwork.
- Whether the part can be removed and brought in, or has to be welded on site.
- For on-site work: a power socket and clear space around the part with nothing flammable.
Frequently asked questions
Can any aluminium be welded?
Most sheet and extrusion alloys weld well. Castings are harder, especially old ones soaked in oil. Some alloys lose strength after welding, and the handyman will tell you at inspection.
Will the weld show?
Yes, you’ll see it. It can be ground and painted. Anodising next to the weld burns off, and a welding shop can’t restore it.
Is there an alternative to welding?
For small parts that carry no load, brazing with special aluminium rods sometimes works. Anything that takes weight needs a proper weld or a new part.
On site or in a workshop?
Depends on the part and the handyman’s kit. Small items come off and get welded in a workshop, gates or garden structures are done on site. The offer will make that clear.
How to order
Describe the part in the app, where the crack is and whether it can come off, and add photos. Welders near you will send offers with their own price and timing. Compare them by reviews and pick one; only that person sees your address.
You pay the handyman directly and they issue the invoice. They stand behind their own weld and will redo it if it cracks through their fault. Hidden flaws in the metal, corrosion and parts later loaded beyond what they were made for are not on them.
Weld aluminium with TIG or MIG? Create a tradesperson profile and jobs from your town will come into the app. You work for yourself and choose how your business is set up.
Order in the app
Describe the job, add photos and the address. Tradespeople send their own prices and dates, and you pick one of the offers.
Open the app