Aluminum filler metal selection chart

Unlike steel, where you generally match “Grade A” filler to “Grade A” plate, aluminum welding requires a strategic choice based on the specific performance requirements of the joint. Are you welding for maximum strength?

Welding aluminum can be a challenging task, but selecting the right filler metal can make all the difference. With so many options available, it can be overwhelming to choose the appropriate filler metal for the job.

That’s where an aluminum filler metal selection chart comes in handy. In this article, we will introduce an aluminum filler metal selection chart that simplifies the process of selecting the right filler metal for welding aluminum, helping you achieve a strong and reliable weld.

Aluminum filler metal selection chart

In terms of joining processes, aluminum and its alloys can be joined with a variety of techniques, such as welding, soldering & brazing, adhesive bonding, and mechanical fastening.

Welding, in particular, is the most commonly used joining process for aluminum. There are several welding processes available for joining aluminum and its alloy assemblies, such as arc welding, stud welding, electron beam welding, laser beam welding, resistance welding, solid-state welding, and oxyfuel gas welding.

However, among these processes, arc welding is the most extensively used, with TIG and MIG welding being the most common.

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Aluminum Grade	Welding Wire
1060, 1100	ER1100
2014, 2036	ER4043, ER5356
2216	ER4145
3003	ER4043, ER1100
5052, 5652	ER5356
5454, 5086	ER5356
6061	ER4043, ER5356
6063	ER4043, ER5356
7075	ER4043

⚖️ The Decision Logic: How to Choose?

When the chart gives you two options (like 4043 and 5356 for 6061 aluminum), how do you decide? Use this “Decision Hierarchy”:

1. Crack Sensitivity (The Safety Rule)

If the weld is highly constrained (rigid fixture, thick plate) or prone to hot cracking:

• Choose: ER4043 (Al-Si). The silicon lowers the melting point and increases fluidity, allowing the puddle to yield during cooling.
• Avoid: ER5356 on 6xxx series if the joint design is poor, as it is more prone to crater cracks.

2. Service Strength (The Design Rule)

• Choose: ER5356 (Al-Mg). It typically has a shear strength of 26 kpsi compared to 15 kpsi for ER4043.
• Note: If you are welding 6061, the heat-affected zone (HAZ) loses 40% of its strength regardless of the filler. However, for fillet welds, the filler metal strength still matters significantly.

3. Aesthetics & Anodizing (The Visual Rule)

• Choose: ER5356. If the part will be anodized after welding, this rod will color-match the base metal (Silver).
• Avoid: ER4043. The silicon will turn Charcoal Black or Dark Grey during the anodizing process, creating a high-contrast ugly weld.

4. Service Temperature (The High-Temp Rule)

• Choose: ER5554 or ER4043.
• Avoid: ER5356 or ER5183 if the component operates continuously above 65Deg C (150 Deg F). High Magnesium alloys are susceptible to Stress Corrosion Cracking (SCC) at elevated temperatures.

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⚠️ The “Fatal Flaw”: Magnesium Silicide (Mg₂Si)

There is one combination you must avoid at all costs:

Never use ER4043 (Silicon) to weld 5xxx series alloys with high Magnesium (like 5083 or 5086).

• The Reaction: The Silicon from the rod reacts with the Magnesium in the plate.
• The Result: They form large precipitates of Magnesium Silicide (Mg₂Si). This reduces the ductility of the weld to nearly zero.
• The Failure: The weld may look fine visually, but it will snap like glass under a load.

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📝 Quick Reference: Alloy Codes

• ER1100: Pure Aluminum (Soft, highly conductive, excellent corrosion resistance).
• ER4043: Al + 5% Silicon (General purpose, high fluidity).
• ER4047: Al + 12% Silicon (Lowest melting point, used for thin castings).
• ER5356: Al + 5% Magnesium (Structural standard).
• ER5183: Al + 4.5% Mg + Mn (High strength marine grade).
• ER5556: Al + High Mg (Maximum strength for armor plate/cryogenics).

Groove Design Chart for Aluminum Welding

Welding aluminum is a popular method for joining parts in various industries, but it requires a proper groove design to ensure a successful weld. The groove design refers to the shape and size of the gap between the parts to be joined.

Using the correct groove design for the specific joint configuration and thickness of the aluminum parts is essential for achieving a strong and reliable weld. A groove design chart for aluminum welding is a helpful tool that simplifies the groove design process by providing a comprehensive list of groove shapes and dimensions.

Below is a groove design chart for aluminum welding and discuss how to use it to select the appropriate groove design for a given joint configuration and aluminum thickness.

TIG welding Parameters Chart for Aluminum Welding

Tungsten inert gas (TIG) welding is a popular method for welding aluminum due to its versatility and ability to produce high-quality welds.

Although, TIG welding requires precise control of various welding parameters to achieve optimal results. Welding parameters such as current, voltage, welding speed, and gas flow rate are critical factors that must be carefully controlled to ensure a successful weld.

To simplify the TIG welding process for aluminum, a TIG welding parameters chart is a useful tool that provides a comprehensive list of recommended welding parameters for different aluminum thicknesses and joint configurations.

MIG welding Parameters Chart for Aluminum Welding

Metal inert gas (MIG) welding is a popular method for welding aluminum due to its speed and ease of use. However, MIG welding also requires precise control of various welding parameters to produce high-quality welds. Welding parameters such as wire feed speed, voltage, and gas flow rate are critical factors that must be carefully controlled to ensure a successful weld.

To simplify the MIG welding process for aluminum, a MIG welding parameters chart is a helpful tool that provides a comprehensive list of recommended welding parameters for different aluminum thicknesses and joint configurations.

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