We are working on a project for a speaker manufacture. They are large grids made from .500 to 1 inch thick 6061 T6 Alm. They are going to test break the first grid. We have done similar projects like this using 4043 Filler Rod in GMAW it flows and welds real good but it is not as strong as 5356filler rod. Would it be woth switching to 5356 filler rod for this type of application because of the higher shear strength 5356 rod gives you?
In my opinion it would be better to weld 6061T6 with 5356 from a mechanical testing point of view. If architectural considerations or anodizing, are required, 4043 is still the best.
Joe, I agree that 5356 will have better mechanical properties, but it is better as far as weathering and anodising color match as well. 4043 darkens in weather exposure, and doesn't color match when anodised, but I prefer to weld with it when I can.
You are correct. 4043 is not good for anodizing. I don't know what I was thinking. I have had architects and fire commissioners require me to use 4043 because it was nice and shiny and looked nice when first welded. I have tried to explain that the weld would tarnish. Of course, the fire trucks were always being polished, so as long the welds were smooth, the truck looked good. Part of the problem is that I wasn't a good enough welder to make the 5356 wet out as nicely as the 4043.
Sounds like you are maybe making something called speaker bumpers? Anyway do you plan to use GMAW because if you do 4043 filler wire will be your best bet 5356 filler wire does not run all that great with GMAW with my experience I have built some things for speaker manufactures in the past sounds similar to what you may be building with 1" 6061-T6.
4643 gives good mechanicals in 1/2" thick on up and still has the same characteristics of 4043.
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