Skilled aluminum TIG welders are hard to find and expensive to keep. For a shop that welds a lot of thin aluminum, that shortage is a bigger labor-cost problem than welding speed. Laser welding changes who can do the work.
What the training covers
Ascent's hands-on training takes 3-4 hours. After it, an operator who has never welded aluminum can weld very thin aluminum, using approved settings, fixtures and supervision. The operator remains responsible for completing the required training, following approved process controls and meeting every laser-safety requirement.
That is a narrower statement than "anyone can weld," and it is meant to be. A few hours teach basic operation on defined parts. They do not replace laser-safety training or welder certification, and they do not prepare someone for every joint and material a shop might see. Results also vary between operators and applications.
Why a laser is quicker to learn
TIG on aluminum has the welder managing a torch, filler wire and often a foot pedal, while judging the molten pool by eye. Thin aluminum makes that harder, because it carries heat away quickly and can distort or burn through without warning.
A laser welder takes several of those jobs off the operator. Approved settings can be saved for each material and thickness, and the wobble head produces a steady, consistent seam. The operator mainly controls the torch position, its angle and its travel speed. Less heat goes into the surrounding metal, there are no hands and feet to coordinate, and repeat parts can be welded with settings and fixtures that are already proven.
That is why a reliable production worker can learn the basics much faster than someone working toward TIG mastery. There is less to master before the welds are good enough to use.
Comparing the labor cost
The gap between a reliable production worker and a highly skilled aluminum TIG welder is wide enough to change how a shop staffs its aluminum work. The figures below are illustrations. Use your own local rates.
| Item | Production worker | Skilled aluminum TIG welder |
|---|---|---|
| Example hourly wage | $22 | $24–$32 |
| Example total cost to the employer per hour | $33 | $35–$48 |
| Prior welding experience | Not required | Usually several years |
| Variables controlled by hand | Few | Travel speed, heat, torch angle, arc length and filler |
| Best suited to | Repeat parts with set procedures | Varied fabrication and difficult custom welds |
With these example figures, the difference in employer cost reaches $15 an hour at the top of the range, or $30,000 a year over 2,000 paid hours. In Canada, the same comparison is about CAD $32 against CAD $60 an hour. Our post on laser technology for entry-level workers works through these rates with production-time savings. For current national figures, see the Bureau of Labor Statistics data for welders, cutters, solderers and brazers. Aluminum TIG specialists often earn more than the overall median, depending on certification, location and industry.
The saving comes from who does the work
In many shops, much of the welding volume is repeat work on thin aluminum parts. With a laser, that work no longer needs an expensive specialist. A reliable production employee trained on the Ascent welder can take over the repetitive welding, and the shop's skilled welder can concentrate on the custom and structural work that really needs that experience.
It is a staffing change, not a pay cut. The cost problem is solved by reassigning the task, and nobody has to earn less.
Before you buy
A handheld laser welder is a Class 4 laser, so plan for laser-rated eyewear (minimum OD 5; prefer OD 7 or 8), an enclosed work area and fume extraction. See our laser safety page.
For how laser welding compares with MIG on different metals, read our MIG comparison, or see the Ascent refrigeration laser welder page for full specifications. The Ascent 2000W handheld welder is USD $28,000 and the 3000W is USD $34,000, with shipping, installation and training at your facility included.
