We never had good luck fusing tanks. Had issues splitting at weld without adding filler rod. Problem went away with filler rod.
Can also adjust heat by concentrating tip more on filler rod than on material if needed. Quicker than modulating pedal.
I never had splitting problems, but should have some filler for 5052. End caps are 0.090. Either,or, tight joints weld fast with a Tig. I have a Syncrowave 250 for this task.
Mig welding aluminum is a fast paced operation. Pretty easy to blow a hole in 1/4". I don't think I want to try it on real thin stuff. Maybe with a spool gun and some 0.030. Mine is primarily set up for structural stuff.
