Top 5 Best welder For sheet metal in 2020 | expert’s choice

You can master sheet metal welding with a bit of practice on the right welders. But unfortunately, welders cannot find the best welder for sheet metal because it is quite challenging to find out the right welder for sheet metal.

You will have to choose from numerous brands and models, which will make you confused. That’s why we have written a complete review and buyer’s guide to help you find the right welder that matches you.

Table of Contents

Top 5 best welder for sheet metal in 2020 | reviews and buyer's guide

Hobart 500554001 Handler | Best overall MIG

Hobart 500554 Handler 190 MIG Welder is famous and versatile in the market. This exoteric welder can weld both aluminum and sheet metal. You can also operate this machine as a beginner as it is effortless to use. It is considered to be the best welder for sheet metal.

Having only 68 pounds makes it portable, easy to transport, ideal for rental shops. It offers a maximum duty cycle of 30% at 130A. 

It can do different types of welding such as aluminum repair, farm equipment, metal sheet repair, metal sculpture, trailer repair, and many other projects. So, it is somewhat highly-priced; well, worth it.

Another most wonderful feature of this MIG welder is spoolrunner 100 spool gun, which reduces “bird nesting” and enhances the feed ability. You won’t need any additional control box or adaptor to connect the SpoolRunner 100 spool gun.

The integrated control system allows the effective use of the welding tool. It also provides a protection feature that causes the wire to be cool down electrically when not used. it is considered to be one of the best MIG welder for aluminum and sheet metal as well.


According to the manufacturer, you can weld from 24 gauge to 5/16″ steel with single-pass, but many skilled welders confirmed that they had welded ½ inch steel without any problem.

The Handler 190 operates on 230V input power and offers an output range of between 25 and 190 amps, allowing users to weld materials as thin as 24 gauge and as thick as 5/16 inch.

Yes, this unit includes high-quality spoolrunner 100, and the wire feeder is cast aluminum.

Yes, but a 7000-watt generator is recommended.



Forney Easy Weld 261, 140 FC-i MIG Welder, 120V, Green

Reputed Americas Forney industries manufacture Forney easy weld 261. They mainly manufacture a family-owned tool, equipment, and accessories.

Forney’s Easy Weld 261 is a highly compact yet powerful tool. It is one of the lightest and most compact MIG welders we saw at just 19 pounds. It is not only affordable but also an excellent performer. Connected to any standard 120V outlet, it offers a smooth feed and makes up to 1⁄4-inch of clean steel welding thanks to its 140-amp capability.

The welder uses no gas. Instead, the flow-core welding method is applied. This system has other health advantages. It saves you the risk of fires and the resulting burns and injuries. It also offers you extra tranquility.

30% duty cycle at 90 Amperes allows you to continuously weld and take advantage of the unhindered peace of mind. The easy Weld 261 is the best welder for the money due to its low price and robust performance.


Yes. As Hobart’s contact tips and Forney easy weld 261 contact tips are the same, that is tweco style.

Yes, you can, as long as you have the PPE.

Somewhere about 14 volts, the minimum energy consumption is 32A. This is the power of approximately 450W.



2020 Weldpro 200 Amp Inverter Multi-Process Welder with Dual Voltage 220V/110V Mig/Tig/Arc Stick 3 in 1 welder/welding

With the MIG, Flux, and TIG welding, 2020 Weldpro 200 Amp Inverter Multi-Process Welder is considered to be the best multi-process welder in this price range. Despite its low price, it works better than most other multi-process welders. It will give you a lot of choices without confusion. You will get a quality package at an affordable price.

Many reviewers say that it is the best welder for automotive sheet metal. It’s a compact machine that is easy to bring on-site and is perfect for sheet automotive welding if you don’t want to complete a job with multiple machines. In TIG and MIG welding, it stands out.

The IGBT inverter technology provides supreme control, which for pros, hobbyists, and beginners are one of the many reasons this model is recommended.

It can even weld metals of all sorts, including aluminum. Nonetheless, you must buy a compatible spool gun to work with aluminum. We gave the model a ranking of 4 and a half stars out of 5 to be a perfect purchase for work or home use.

The optical display used in this device is effortless to read under light or darkened conditions. However, the monitor allows the user to show the wire speed and set the amp to repetitive welding.


Yes, Tiny 1-2 lb. can be used for the welder. The w adapter is fitted with 4 “spools and the medium 10-12 lb. It doesn’t take 40-44 lb. However. Spools of twelve inches.

TIG by C25 while using a MIG welding mixture air. You should weld only ferrous metal since this is just a DC unit. It has no high-frequency start and no variable amperage during the welding process. If tungsten is electrically soft, you simply touch it and raise it.

This solder emits 27 volts per minute and 550 inches.



LOTOS MIG175 175AMP Mig Welder with Free Spool Gun, Mask, Aluminum Welding Wires, Solid Wires, Argon Regulator, Standard MIG Gun

Lotos MIG 175 is the welder in your garage any serious contractor would like. During my work with my welding machine that I thought was the most famous one in the market, I found the Lotos MIG 175 in the garage of a friend.

This is the LOTOS MIG175 that provides an output of 175 amps with a smooth welding operation. It has nearly all the features you like for welding. It has its gas regulator and can also be used for the flow center. It is specially made. With this welder, you can weld practically anything from steel to aluminum or even sheet metal

I award it a 4.5-star rating out of five not just from its versatility, but from the purchase with my experience with the MIG 175 Lotus welder. It includes a MIG welder, a welding mask, an argon controller, a horse with argon, a ground clamp, and rope, a MIG spooling device, and a MIG torch.

I was in the welding business and have purchased many welders till now. Very few of them can come in the kit with too many side items. There is not one downside to the service of this system that I have highlighted.


This welder takes 30 AMP less than 220 V. Therefore; you will have more than 7000 Walt of your generator.

No, you can only use it on 220/240v. But you can use lotos MIG 140 on 110v, which is also a nice one.

No gas is required to weld aluminum.

Duty cycle is 30% @ 135A.



2018 AHP AlphaTIG 200X 200 Amp IGBT AC DC Tig/Stick Welder with PULSE 110v 220v 3 YEARS WARRANTY

The AHP AlphaTIG 200X Welder is an economic tool, we might claim. You should find that this machine works well and will satisfy you with both its TIG and stick option. It is built for experienced welders or those who view it as a hobby, and it is the main advantage.

This welder machine can be used with 1/8′′ space metal at a power supply of 40-80 amps. The metal used can exceed 3/8 “(@200 amp) thick. One of the best things about this welding machine is that the inverter technology of Fairchild IGBT provides you the full production.

It provides standard TIG welding on aluminum, steel, and effective welding of thinner gauge materials. This welding unit can not only be used by professionals as it was developed by the fabricator for freshers and people who like welding in the hobby.

A lot of power for small bucks is provided by the AlphaTIG 200X. You will have more welding capacity than you ever wanted with a duty cycle of 60 percent at 200 Amps for TIG welding.

Ultimately, 60% duty cycle @ 200 A means that you can weld at 200A for six minutes. Then you will have to wait for four minutes until the system refreshes. you can restart your project again after that.

200 Amps at 220 Volts and 140 Amps in 110 V outlets are the most current for the machinery. Want to learn more about it read our detailed review


A single phase of 110 to 220 Volts is equipped to run AlphaTIG. You can select either AC or DC output current, depending on your welding work.

Two main and four touch operations are referred to in the 2T/4T section. For beginners, 2 T mode is the simpler, while 4T is a little more complex. In 4T mode, the welding process is completed over the stages.

AHP Alpha TIG is not a solderer for MIG. But primarily, a TIG welder provides you with a stick soldering option when the TIG isn’t suitable.



Sheet metal welding tips and tricks

The main problem of sheet metal welding is warping and burn through. In this section;  we are going to share some tips and tricks to solve this.

MIG welding sheet metal tips

Use a filler metal that is thinner than the base metal. We recommend .023 or .024-inch wire for almost all light gauge sheet metal work. But if your material is 18-gage thick or even more, you may use a .030 inch wire. We recommend using a wire that is certified by the American Welding Society; for example, ER70S-6 has a weld puddle that wets out well.

Never use pure CO2 as shielding gas as it carries more heat. We recommend using a shielding gas that is highly argon based, for example, 75% argon/25% carbon dioxide. It will help you to make weld with less spatter.

You will never want to weld sheet metal with flux-cored wires as it puts more heat into the base metal causing burn-through.

TIG welding sheet metal

For TIG welding sheet metal, our first recommendation is to use a ceriated tungsten, and thoriated tungsten is the second recommendation. Do not use a 1/8 inch tungsten electrode to use a 1/16 inch tungsten electrode with a diameter down to .020, .040. It may help you to prevent burn-through because a smaller electrode performs better than the larger one in lower heat settings.

Though ER70S-2 filler metal is the most popular choice for metal steel, silicon bronze does not leave behind. It reduces the heat required to weld it and also finishes nicely. Thinner metal should be thinner than the base metal so that the base metal can not be overheated.

Do not whip or weave the torch to prevent burning and warping; the longer the arc will be in a place, the hotter it will get. Take a straight line always and use the quickest possible travel speed that holds a nice bead profile. A push technique from the MIG gun is another way to avoid burning through. In relation to the pulling of the fuselage, which guides the wire on the heater portion of the fuse – raising the risk of an explosion, it points to the colder edge of the base metal and puddle.

Stitch weld

Inappropriately distributed heat creates distortion and damage that is harmful to parts that will be joined. Distribute heat as equally as possible to reduce the warping. It can be achieved with a technique that requires the creation of a series of periodic or stitch welds.sheet metal welding tips; stitch weld

It is also termed as “intermittent ” weld. In this process, you will have to make a discontinuous weld by keeping gaps in between two welds.

Dissipate heat

Place the heat-affected region in contact with the backing or chill bar to dissipate the heat faster than atmospheric cooling alone. It can be so simple as to clamp on the back of the welding with a metal bar (typically copper or aluminum because they dissipate the heat best). Stitch weld also helps to dissipate the heat produced while welding.

Final verdict

Hope you have liked our well researched article on best welder for sheet metal. Though Hobart 500554001 Handler is our first choice, all the other four will work efficiently on sheet metal. If you want both TIG and stick option on your welder AHP alpha 200x would be the best choice for you which is also a budget friendly welder with tons of features.

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