ER5356 Aluminum Wire: MIG & TIG Settings for Marine & 5xxx Alloys
High-strength aluminum wire for 5xxx series alloys. Runs 50 to 250 amps on DCEP or AC, rated for flat, horizontal, vertical up, overhead. Amperage chart by diameter below.
ER5356 is a magnesium-alloyed aluminum filler wire for MIG and TIG welding. It has higher shear and tensile strength than ER4043 and produces a better anodized color match with the base metal. It is the required filler for 5xxx series aluminum alloys (5052, 5083, 5086) and is preferred for structural marine and high-strength aluminum applications. The 5% magnesium content makes it stiffer and more rigid than 4043, which can cause MIG feeding issues in long cable runs. It is also more crack-sensitive than 4043, particularly on 6xxx base metals. For marine, structural, and anodized-appearance applications, ER5356 is the correct choice.
What This Means in Practice
ER5356 means: ER (electrode rod for MIG/TIG) + 5356 (Aluminum Association alloy 5356, an Al-5%Mg alloy). The 5xxx series aluminum alloys are magnesium-alloyed for strength and corrosion resistance.
What Amps for ER5356?
| Diameter | Amperage Range |
|---|---|
| .030" (0.8 mm) | 50 - 130A |
| .035" (0.9 mm) | 70 - 180A |
| .045" (1.2 mm) | 100 - 250A |
Amperage by Individual Diameter
.030 ER5356 Amperage
Set .030 ER5356 to 50 - 130 amps. Run DCEP or AC. This is the smallest available size. Best for vertical-up and overhead where you need a small, controllable puddle. Start around 90A.
.035 ER5356 Amperage
Set .035 ER5356 to 70 - 180 amps. Run DCEP or AC. This is the most commonly used ER5356 size. Start at 125A for flat work, drop to 70-113A for vertical-up.
.045 ER5356 Amperage
Set .045 ER5356 to 100 - 250 amps. Run DCEP or AC. Largest available diameter. High deposition for flat and horizontal fillet welds on thick plate. Requires 100A minimum to run properly.
ER5356 Suitability Scores
How well this electrode matches common applications. Not a quality rating. all AWS-certified electrodes meet their specification.
What Is ER5356 Good For?
5052, 5083, 5086 aluminum (required filler).
Structural marine applications.
Any application where the weld will be anodized and color match matters.
High-strength aluminum fabrication where fillet weld shear strength is critical.
Boat hulls, fuel tanks, truck bodies.
Where ER5356 Falls Short
More crack-prone on 6061 and cast aluminum than ER4043.
MIG feeding is harder because the wire is stiffer and requires shorter cable runs or push-pull guns.
Not recommended for 6xxx base metals in service above 150 deg F due to stress corrosion risk.
More operator skill required than ER4043.
Welding With ER5356
Arc Behavior
Slightly stiffer arc than ER4043. The higher magnesium content makes the filler rod feel firmer in your hand. The puddle requires more heat to flow, so amperage settings run slightly higher.
How to Move
Same TIG technique as ER4043 but push heat harder. The higher melting point means you need more amperage or slower travel to get proper fusion. MIG settings run 10-15% hotter than ER4043 on the same thickness.
What the Puddle Does
Less fluid than ER4043. The puddle wets out but does not flow as freely. The finished bead is slightly duller and rougher in texture. It does not produce the mirror-finish that ER4043 does.
Troubleshooting
If the bead looks dull and rough, that is normal for ER5356. Do not try to fix it with more heat. If you see hot cracks on the crater at the end of a bead, fill the crater before lifting the arc.
ER5356 Size by Material Thickness
| Wire Size | Material Thickness | Application |
|---|---|---|
| 1/16" | 1/16" to 1/8" | Thin 5xxx-series aluminum |
| 3/32" | 1/8" to 1/4" | Standard 5xxx and 6xxx aluminum |
| 1/8" | 1/4" and up | Structural aluminum plate |
From the Field
ER5356 is the structural aluminum filler. Higher shear strength than ER4043, better fatigue life, and it color-matches after anodizing. Use it on 5052, 5083, 5086, and 5454 aluminum. It also works on 6061 when the joint will be anodized. The catch: ER5356 hot-cracks on high-silicon base metals and castings. Check the AWS filler metal selection chart before picking ER5356 over ER4043.
Bottom Line
Structural work is where ER5356 belongs. When ER5356 is wrong for the job, reach for ER4047.
Setup & Safety Reference
How to Store ER5356
Keep sealed. ER5356 is more prone to surface oxidation than ER4043 due to magnesium content. Use within 2-3 days of opening in humid environments.
Shielding Gas for ER5356
| Gas Mix | Common Name | When to Use |
|---|---|---|
| 100% Argon | Argon | Standard for MIG and TIG. Most applications. |
| 75% Ar / 25% He | Ar/He | Thicker aluminum. Better penetration. |
| 50% Ar / 50% He | Ar/He 50/50 | Heavy aluminum plate and structural work. |
Higher-strength aluminum wire. Same gas rules as ER4043. Helium reduces magnesium oxide buildup.
Preheat & Interpass Temperature for ER5356
Not required for thin sections. For material over 1/2 inch, preheat to 200-250F. Do not exceed 250F on 5xxx-series base metals with over 3% Mg to avoid stress corrosion cracking.
| Base Metal Thickness | Minimum Preheat (°F) |
|---|---|
| up to 1/2" | Not required |
| over 1/2" | 200°F |
Maximum interpass temperature: 250°F
Shielding gas flow rate: 25-35 CFH
Source: AWS D1.2, manufacturer data
Wire Feed Speed for ER5356
Requires spool gun or push-pull gun. Use 100% argon. ER5356 is stiffer than ER4043 and feeds more consistently through longer gun cables.
| Diameter | Amperage | Wire Feed Speed (IPM) |
|---|---|---|
| 0.030" | 70-140A | 300-600 IPM |
| 0.035" | 90-180A | 250-500 IPM |
| .045" | 120-250A | 200-400 IPM |
Deposition Rates
| Diameter | Deposition Rate |
|---|---|
| 0.030" | 1-3 lbs/hr |
| 0.035" | 2-4 lbs/hr |
| .045" | 3-6 lbs/hr |
Fume Generation
Rating: Low
Typical fume rate: 0.1-0.3 g/min
Aluminum wire with magnesium. Low fume. Ozone is primary hazard.
Common Brand Names for ER5356
Look for Lincoln Electric SuperGlaze 5356 at your supplier. 3 companies produce ER5356-classified rods.
| Manufacturer | Product Name | Notes |
|---|---|---|
| Lincoln Electric | SuperGlaze 5356 | |
| Hobart | Maxal 5356 | |
| Harris | Harris 5356 |
Full Specs
| Property | Value |
|---|---|
| AWS Classification | ER5356 |
| Process | Aluminum MIG/TIG (GMAW) |
| Polarity | DCEP, AC |
| Positions | flat, horizontal, vertical up, overhead |
| Penetration | medium |
| Coating Type | solid wire |
| Tensile Strength | 38,000 psi |
| Yield Strength | 17,000 psi |
| Elongation | 18% |
| Base Metals | 5052 aluminum, 5083 aluminum, 5086 aluminum, 5454 aluminum, 5xxx series aluminum |
| Shielding Gas | 100% Argon, 75% Ar / 25% He, 50% Ar / 50% He |
| Gas Flow Rate | 25-35 CFH |
| Max Interpass Temp | 250°F |
| AWS Specification | AWS A5.10/A5.10M:2021 |
ER5356 Questions
Is ER5356 stronger than ER4043?
ER5356 has higher shear strength (26 ksi vs 15 ksi for ER4043) and higher tensile strength (38k psi vs 26k psi). For structural aluminum applications, ER5356 is the stronger choice.
Can ER5356 be used on 6061 aluminum?
Yes, but ER4043 is often preferred for 6061 because it flows better and is more crack-resistant. ER5356 on 6061 works but requires more attention to technique.
Why does ER5356 match color better when anodized?
ER5356 contains no silicon, so anodized welds match the base metal color. ER4043 contains 5% silicon which turns dark gray or black when anodized, creating a visible weld line.
Where to Buy ER5356
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Manufacturer Data Sheets
External links to standards bodies and manufacturers. These leave GageRef.
Reference data only. Verify all settings against manufacturer documentation and the applicable welding code before use. Amperage ranges are starting points that vary by position, fit-up, and material. Welding involves serious injury risks including burns, electric shock, fume exposure, and fire. This site does not replace proper training, certification, or employer safety procedures. See full terms of use.
Data sourced from AWS A5.10/A5.10M. Amperage ranges are approximate starting points. adjust based on position, fit-up, and material thickness. Always follow manufacturer recommendations and applicable codes.