[Clem1640]

We opted for MIG, rather than TIG. Cost of equipment was the major deciding factor. We weld Al with MIG. We did not benefit from professional instruction (wish we had).

I'd love to do TIG, but in defense of MIG, the learning curve is not so steep and in our 2nd year of welding, we only broken two welds. Pretty good considering the severety of BREAKAWAY competition. Our robot has been through 7 competitions so far (one to go - Ramp Riot) and a goodly number of demos, so it's gotten a lot of abuse.

Two welding helmets are a must. Self darkening (electrochromic). Expensive but essential.

You'll need isolation. Welding curtains will do.

Make certain the welding area is absolutely cleared of easily flammable material (sawdust, paper,...) before welding.

Keep a fire extinguisher, bucket of water and bucket of sand (to quench burning Al) handy. Safety should be first-of-mind while welding.

We have found the benefits of welding to be substantial. It allows more freedom of design and is an enormous help in weight management.