Alcotec - Aluminum Welding Wire manufacturing and support (2024)

FAQs

What is the best aluminum welding wire? ›

The most commonly used MIG aluminum welding wires are ER4043 and ER5356. ER4043 is a general-purpose MIG welding wire used to weld 2014, 3003, 3004, 4043, 5052, 6061, 6062, and 6063 aluminum alloys. The welds provide high ductility and excellent resistance to cracking.

Briefly, 4043 is easier to weld with and provides a better appearance. 5356 is stronger, which is not really important for groove welds. However, the picture changes a bit if you are assembling a structure using fillet or lap welds.

5554 or 5754 is used to weld alloys with low Mg content like 5052, 5154, and 5454. 5356 is used to weld intermediate-strength alloys such as 5086 and 5083. Sometimes 5183 is selected for increased mechanical properties. 5183, 5556, and 5087 are used to weld the highest-strength 5XXX alloys.

6061 cannot be welded autogenously, you will have severe hot cracking. You must have a filler metal of a different composition than 6061, that's why you will not find any 6061 filler metal. Use the 4043 or 5356 and a slightly convex bead to help insure you have enough filler metal added to prevent cracking.

Aluminum as a filler metal has the same oxidation problems as all aluminum. When left open, either on the shelf or installed on the welder, aluminum filler wire will oxidize, which can lead to an erratic arc.

5356 aluminum MIG wire is stronger than 4043 aluminum MIG wire. For applications where high strength is critical, 5356 is the preferred choice.

Shear Strength - 4043 has lower shear strength than that of 5356 (see Fig 1). This may be of consideration when calculating the size of fillet welds.

It is designed to weld 5xxx series structural alloys and 6xxx series extrusions, basically anything other than castings, because castings are high in silicon. Its one limitation is that 5356 is not suitable for service temperatures exceeding 150 degrees Fahrenheit (65 degrees Celsius).

Even if you are welding on 6061, which is a very common alloy, if you use too much heat and too much penetration in that base metal, there is a lot more chance of it cracking, so in some cases 4043 is the preferred choice with this alloy. However, people do use 5356 to weld 6061 often.

In the United States, solid aluminum wires made with AA-8000 series aluminum alloy are allowed for 15 A or 20 A branch circuit wiring according to the National Electrical Code. The terminations need to be rated for aluminum wire, which can be problematic.

What wire is best for MIG welding aluminum? ›

Some of the most common types of aluminum MIG wire include: ER4043 aluminum MIG wire: This is a general-purpose aluminum MIG wire that is good for welding most types of aluminum. It is not as strong as some other types of aluminum MIG wire, but it is easy to use and relatively inexpensive.

Flux core welding is typically used for welding mild steel and low-alloy steel. However, there are flux core wires available that can be used to weld other metals, including stainless steel and aluminum. It's important to choose the right flux core wire for the metal you're welding.

Pick the right tungsten electrode or rod—the best choice for aluminum is typically a pure tungsten rod. Take the time to prepare your aluminum by cleaning and preheating it.

With color match as our prime consideration, the most appropriate filler for this application is alloy 5356.

4043 aluminium alloy is a wrought aluminium alloy with good corrosion resistance typically used as filler material for welding of aluminium parts.

ER5356 MIG welding aluminum wire

ER5356 is another commonly used aluminum welding wire for MIG welding. This wire is particularly suitable for applications requiring high tensile strength and good corrosion resistance. It is often preferred for marine and structural welding due to its ability to provide strong welds.

Since the most commonly used aluminum wires, 4000- and 5000 series, have different mechanical properties (4000 series is softer; 5000 series is harder and more abrasive) they require different tension settings.

5XXX alloys.

These alloys come in very strong sheets and plates. They can be readily welded with 5356, 5183, or 5556 filler metal.