Yes, the thickness of the workpiece can determine how we perform a welding procedure. That’s because, among other things, the workpiece thickness can determine the amount of heat needed for effective welding. Thinner workpieces do not require as much heat as thicker materials do. If you don’t use the right welding method on a dense material, the welding aluminum extrusions may lack temperature consistency. This may result in cracking or distortion of the material. TIG welding is ideal for metal thicknesses of between 1mm and 6.5mm depending on whether it is a fillet weld or butt weld. MIG welding can weld fillet welds of up to 25mm thickness.