6 Best Welder For Sheet Metal – Ultimate Buying Guide, FAQs And Reviews

Welding sheet metals isn’t an easy task, yet it isn’t impossible. With enough practice and the right equipment, mastering the art of sheet metal welding can soon be your reality. However, finding the best welder for sheet metal is imperative to succeed at this.

One of the problems regarding this is that brands and sellers don’t usually promote their welders as adequate for welding of sheet metal. From the wide sea of MIG, TIG, as well as multi-process welders, some can do the job better than the rest. That’s why we compiled a list of reviews for the top products on the market right now by outlining the specifications, the pluses, and the minuses. These are accompanied by the features you should consider when shopping as well as answers to frequently asked questions. Let’s go!

Reviews Of The Best Welder For Sheet Metal Models On The Market Right Now

1. Hobart 500559 Handler 140 MIG Welder 115V

Sheet metal is associated with TIG welding in most instances. But this in no way means that it can be fused solely with this process. Instead, MIG welding comes in handy in many situations, as well. This makes this model one of the current ones that people are looking for on the market.

Mainly, this is as a result of the efficiency it offers at an affordable price. As it’s an easy machine to operate, both professionals and hobbyists can take advantage of the numerous settings it incorporates. Although its amperage range is low, it’s still capable of performing the welding tasks efficiently. In fact, this low range prevents blowing through the joint, providing a seamless welding experience.

Despite this, though, users report certain downsides that are related to the welding chart lacking accuracy. This can be a problem when trying to determine exactly how much you should cut.

For more detailed specifications, check these out:

  • Power: 115 volts
  • Duty cycle: 20%
  • Amperage range: 25-140 amps
  • Can weld up to 1/4 mild steel
  • Weight: 57 pounds
  • Dimensions: 19x11x13 inches


  • Affordable
  • Easy to operate
  • Supports MIG welding


  • Low amperage range
  • Inaccurate welding chart

2. PRIMEWELD TIG225X 225 Amp IGBT AC DC Tig/Stick Welder

What’s special about this model is that it gives users an option to switch between AC and DC output in order to go through various types of sheet metal. That’s why it’s suitable for everyday use around the house or at the worksite.

Among the notable features that it possesses are the Superflex torch that works well for welding in low amperage and the foot pedal that can be easily utilized. Yet some users complain that the pedal isn’t very comfortable for longer periods of time. As for the range, this welder has a higher amperage range than many other sheet metal models. When you consider that this comes at an affordable price, it comes worthy of checking out.

Finally, it should be noted that users can perform only TIG welding tasks with this one. More specifications are as follows:

  • Power output: 110 / 120 volts
  • Amperage: 225 amps
  • Can weld 3/8 inches mild steel
  • Warranty: 3 years
  • Weight: 90 pounds


  • AC and DC output
  • Supports more types of sheet metal
  • Superflex torch
  • Affordable price


  • Uncomfortable foot pedal

3. AHP AlphaTIG 200X 200 Amp IGBT AC DC TIG/Stick Welder

Some welding machines aren’t able to perform welding tasks that involve aluminum sheet metal successfully. Not this one. AHP Alpha TIG 200x has the needed amperage to do this smoothly and without any issues. Actually, this is among the most positive options that users like about it.

When it comes to beginning with the process, it incorporates a starter that doesn’t require your touch and has a high frequency. Thanks to it, the arc forms at once and you can start welding. However, it should be mentioned that there are a few cons associated with it. They aren’t too serious and revolve around the lack of comfort in the pedal and the ground clamp being in poor quality.

In case you’re curious for more, these are the specifications to have in mind:

  • Warranty: 3 years
  • Pulse: 200 Herz
  • Thickness of aluminum it can weld: 1/4 inches
  • Voltage: 110/220 volts
  • Balance: 30-70 %


  • Can weld aluminum sheet metal
  • No-touch starter
  • Quickly-forming arc
  • Long warranty


  • Lack of comfort in the foot pedal
  • Poor quality of the ground clamp

4. Weldpro 200 Amp Inverter Multi Process Welder with Dual Voltage

This welder is especially suitable for welding sheet metal on cars. The fact that it’s versatile and operates well for TIG and MIG tasks gives people the freedom to work with it no matter the occasion.

Since the machine has parameters that are internally previously set up, the needed settings for welding sheet metal are known. Yet this restricts the adjustments that users can make, which is why they consider this as a slight downside. Still, there are plenty of things they have control of.

Another useful detail is that this is a small and compact product that fits nicely everywhere and is portable. And it contains all needed options sparing people from purchasing additional machines for some of the tasks. Having in mind its affordable price and the fact that you get a multi-process welder for the money, it’s obvious that this is a welder worthy of your attention.

Before we get to the specifications, though, you should be aware that the yellow color can get dirty fast. These are more details:

  • Voltage: 110/220 volts
  • Duty cycle: 30 %
  • Welding thickness: 0.315 inches
  • Weight: 30 pounds


  • Versatile
  • Small and compact
  • Multi-process welder
  • Affordable


  • Lacks many adjustment options
  • Yellow color gets dirty quickly

5. Forney 309 140-Amp MIG Welder

This MIG welder incorporates some premium features that many expensive models have but come at a relatively affordable price. Some of them include its portability and compactness, accompanied by the ability to handle various wire spools.

Moreover, it has a feeding system with aluminum wire. Due to this, it’s durable and can operate successfully during all welding tasks. Not to mention that many of the tasks performed by machines suitable for MIG and flux core welding can be done on this machine, as well. Another helpful detail is that all of its parts are replaceable and it can be set up easily and quickly.

However, as a possible downside, we’ll point out the poor customer service, according to some users, and the lack of instructional materials that come with it.

More specifications are:

  • Welding thickness: maximum of 1/4 inches
  • MIG torch: 10 feet
  • Weight: 56 pounds
  • Input power: 115 volts
  • Power output: maximum of 140 amps


  • Portable
  • More wire spools are supported
  • Durable
  • Can perform MIG and flux core welding tasks
  • Replaceable parts


  • Lack of instructional materials
  • Poor customer service

6. SUNGOLDPOWER ARC MMA 200A Welder Dual 110V 220V IGBT Hot Start Welding Machine

Although the brand may not be familiar to you at first glance, it offers some quality machines for welding sheet metal. This model embraces the IGBT inverter technology fully, maximizing its performance. Connected to this, it has advanced controls and a dual voltage that comes in handy when welding in different parts of the house or worksite. A detail that users like is the digital screen that clearly shows the amps.

To prevent overheating and damages that may appear as a result of that, it consists of arc force protection, a hot start, anti-sticking, and thermostatic control. The electrodes can be simply removed, as well.What’s more, buyers should be aware that it works with an AC plug. Also, it has a low weight and is small, allowing users to take it with them wherever they go.

Despite all of this, users report that they experienced troubles with maintaining the arc and the rod holder not being very professional.

For more specifications, see these:

  • Frequency: 50/60 Herz
  • Welding thickness: 1-20 millimeters
  • Weight: 14.99 pounds
  • Efficiency: 85 %
  • Voltage: 110/220 volts
  • Output power: 20-200 amps


  • Lightweight
  • New inverter technology
  • Affordable
  • Overheating protection


  • Issues with the arc maintenance

Buying Guide: What To Consider When Shopping For The Best Welder For Sheet Metal

Budget And Costs

Of course, your budget or how much money you have set aside for buying a welder can determine the final decision. That’s because no matter how much you like a certain welder, you can’t get if it’s way above your budget.

Once upon a time, quality welders used to take plenty of cash off your budget. That has changed now as many affordable models have become available to users. In fact, some of these cheaper models can even perform better than some expensive ones.

Naturally, you can’t compare high-end models with cheaper ones. But, everybody knows that famous brands can increase the price because of what the brand represents as well as its goodwill.

And if you find a cheaper yet quality welder that is suitable for your DIY projects or home usage, you shouldn’t think twice. On the other hand, some cheap models can break apart shortly after purchase, so make sure you stay away from those.

Size And Weight

Both size and weight contribute a lot towards the mobility of the welder for sheet metal. And how easy it is for you to transport it can be an important factor to consider.

If you’re welding only at home and don’t plan to do that outside of your home, then this may not be an issue. In this case, you can purchase even heavier and bigger welders. However, if you’re moving from one job to the next, then the importance of a mobile welder is increased.

Furthermore, machines that operate with inverter technology are deemed to be lighter.

Personal Preferences And Needs

Your needs are driven by your current welding job as well as the tasks you are going to perform once you buy the welder. With that being said, some users immediately go for TIG welders, which are commonly used for sheet metal welding. For instance, tanks made of stainless steel often require a strong and tough TIG welder.

But going with a TIG-only solution that may be a mistake. That’s because you’ll quickly find out that a MIG welder can help in some aspects of the task. Speaking of a MIG welder, it may not give you the sleep and smooth finish you desire, but it’s the most economical solution for metals that already have a coating or ones that don’t need an ornamental finish.

Further, some welding projects require both MIG and TIG welding. That’s why multi-process welders are often utilized when the user is interested in a heightened versatility in the workplace.

Amperage Settings

Having multiple settings regarding the welder’s amps go a long way toward increasing the adjustability and performance of the model. The significance of having various amperage settings may elude some.

Instead, they are important because different types of sheet metals require different levels of heat. Just to illustrate, stainless steel as a metal is tougher than, let’s say, aluminum. And the amperage plays a vital role here to achieve the desired and professional weld.

Duty Cycle

This feature is very specific to the welders and the welding industry. That’s why we’ll begin by explaining it a bit. The duty cycle refers to the period the welder works nonstop before the user needs to shut it off to cool the welder down. Further, it’s most often measured in percentage. Generally speaking, if you’re welding thicker metals, a longer duty cycle is desired.

Additionally, welders with a higher price written on the price tag tend to have a higher percentage of the duty cycle. That isn’t the case with cheaper models. These have shorter duty cycles.

Another interesting aspect connected to the duty cycle is its inverse relationship with the model’s amperage. That means that if the duty cycle is longer, the welder’s amps are lower and vice versa.

User’s Experience

As surprising as it may sound to some, you can use your experience to guide you to the most suitable welder for sheet metal. In fact, becoming better at your job and increasing your skills is dependent on the quality of the welder.

Moreover, newcomers in the industry may benefit exceedingly from a simpler model that has fewer options and settings. That way you can easily get to know the whole process as well as the machine and become prepared to take on more complex tasks. More experienced users can go for more complex welders. Even though the learning curve is steeper when it comes to these machines, they still present plenty of possibilities for adjustments and successfully completing the task at hand.

Frequently Asked Questions (FAQs) About The Best Welder For Sheet Metal

Why sheet metal welding is different from the rest types?

Answer: As a type of metal, sheet metal is made into flat pieces as a result of a special manufacturing process. Sheet metal is used in many everyday industries and objects. For instance, sheet metal is found in automotive bodies, in architecture when building roofs for buildings, constructing medical tables, and more. As such, the welding procedure for sheet metal is specific when compared to other types of metals.

Can I weld sheet metal with a flux core welder?

Answer: The general rule of thumb is that flux core welders aren’t really used for welding thin metals. That’s usually below twenty gauges. Subsequently, flux core processes are meant for thicker pieces of metal. Only that way users will get effective results they can be proud of.

What type of welder is better for welding sheet metal?

Answer: Both MIG and TIG welding are used for sheet metal welding. If you want to separate them a bit, MIG welders are more efficient when you’re working with denser metals. The situation is different with TIG welding with which thinner pieces of metal are welded better.

A Final Word

In conclusion, it’s clear that the best welder for sheet metal should possess some suitable features for seamless operation and successfully completing the tasks at hand. While there are some models that work solely for MIG welding and perform well in this field, there are others that support both TIG and MIG or work like TIG welders. Therefore, the choice comes to the preferences of the users. Also, as we mentioned earlier, they should look into the technology that the welder incorporates and its efficiency in cutting through various types of sheet metal. But this is just the beginning. There are many details that determine people’s final choice of which machine to get.

So, what is your decision? Which one of the machines we discussed piques your interest? Or do you maybe own one of them? Share your opinions and experiences with us here in the comments section. Happy shopping!


Edward, a seasoned welding expert, shares his extensive knowledge and insights on Welderit.com to help you enhance your welding skills.

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