Welding alloys for aluminum

By countryboy Date 11-24-2010 01:15

I am MIG welding 5052 aluminum to 6061 aluminum, both 10 gage material. Can I use 4043 wire for this application, or 5356 since this would match the 5052? Also, does anyone know if there's a problem welding 6061 with 5356 wire? I know 4043 is the best alloy, but the 5356 feeds better. Thanks for your input!

By DaveBoyer (*****)

Date 11-24-2010 01:52

You should use the 5356 on this joint due to the 5xxx material. 5356 is fine for 6xxx aluminum, it gives a better color match particularly if You get the parts anodised. I prefer the way 4043 runs, however, and feeding it isn't a problem with a spool gun.

By Tommyjoking (****)

Date 11-24-2010 02:10

"I know 4043 is the best alloy, but the 5356 feeds better." Well I am not sure about that but 4043 is the most common filler and it has the most applications.

I think your choice really depends on the kind of service you expect. If there are elevated temperatures, or repeated heat cycles, then 5554 or 4043 would be the will be the best, the other alloys will crack out in this combination with heat exposure over time. If strength of the weld is a primary concern then 5183 would be my choice. If the metal is subject to vibrations or needs to be worked after welding then I would go with 5356. If you have a lot of welding to do some of these alloys may become cost prohibitive so knowing exactly what it will be exposed to can become crucial.

Good luck with it
Tommy

By Mike Sherman Date 11-30-2010 13:35

You can weld 5052 with either a 4xxx or 5xxx series filler metal because is has around 2.5% magnesium. 5xxx series alloys with higher magnesium should be welded with a 5xxx series filler. The 5xxx series filler that is suitable for elevated temperatures is 5554. The 4043 will be okay at elevated temperatures as well. The 4043 will have acceptable but lower strength and ductility than the 5356. The decision on which filler to use should be based on service conditions in conjuction with the alloys.