I would use a minumum 3/8" for the flange, 1/2" would be better. What kind of equipment is she using? If it's tig or mig then it's pretty easy. Stick is a bit harder on thin stuff but doable. I managed to weld my IC pipes with a little AC stick machine but it wasn't fun.
Be careful with the fumes from aluminized tubing....really nasty stuff.