Short circuit transfer mig short arc tig and pulsed tig welding processes provide the most control over the heat to address these challenges.
Tig welding thin aluminium sheet.
Another rule of thumb for tig welding sheet metal thicknesses is try not to use a filler rod that is thicker than the metal you are welding.
Gas tungsten arc welding gtaw has traditionally been considered the go to process for welding aluminum because of the high weld integrity and aesthetic appearance the process provides.
I used 1 16 1 6m 4043 rod for this outside corner joint in 040 and it worked out ok.
Using this process enables more than effective work on thin materials as it provides high precision and high quality work.
Tig welding for sheet metal using a tig welders means that one can work on materials of 26 gauge.
However welding aluminum presents some challenges from controlling heat input to dealing with the oxide layer.
But that is only a guideline.
Using too small a filler rod can be a problem too.