Newer automobile designs aim at reducing vehicle weight. Driven by this need light metal industry is experiencing some exciting developments. One of the most widely used light metal is aluminum. As use of aluminum as an alternative material grows, manufacturers face newer challenges. These new challenges are development of new aluminum alloys, joining of different types of aluminium alloys and improvement in weld quality of welds and weld repairs. One of the technologies being explored by the fabricators of aluminum is pulse gas metal arc welding (GMAW-P). This paper explores difficulties in joining of newer varieties of aluminum alloys and how GMAW-P can help in meeting newer challenges of welding of aluminum.