Aluminum MIG/TIG

GMAW and GTAW with aluminum alloy solid wire for aluminum fabrication, marine, and automotive applications.

Aluminum MIG (GMAW) and TIG (GTAW) wire is classified under AWS A5.10. The two dominant alloys are ER4043 (5% silicon) and ER5356 (5% magnesium). Choosing between them depends entirely on the base metal alloy and the end use. Using the wrong filler on aluminum can cause cracking, porosity, or corrosion in service.

ER4043 is the default for 6xxx series aluminum (like 6061) and all cast aluminum alloys. The silicon content improves fluidity, reduces hot cracking, and produces a smoother bead. The trade-off: 4043 welds are softer, do not anodize to match the base metal color, and have lower shear strength than 5356 welds.

ER5356 is required for 5xxx series aluminum (marine alloys like 5052, 5083, 5086). It is also the correct choice when the finished part will be anodized, because 5356 welds anodize to a similar shade as the base metal. ER5356 has higher shear and tensile strength but is more crack-sensitive and does not flow as easily.

Aluminum demands a spool gun or push-pull system for MIG because the soft wire jams in standard liner assemblies. TIG is the preferred process for thin aluminum and critical work. All aluminum welding requires pure argon shielding, thorough cleaning of the oxide layer before welding, and higher travel speeds than steel to manage heat input.

Aluminum MIG/TIG Electrodes

At a Glance

Choosing the Right Aluminum MIG/TIG Consumable

With 3 options in this category, the choice comes down to the base metal alloy and the service environment. The comparisons below break down the specific differences.

Comparisons

Application Guides

Related Resources