{"id":1116,"date":"2018-10-08T14:00:49","date_gmt":"2018-10-08T18:00:49","guid":{"rendered":"http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/?p=1116"},"modified":"2022-06-06T18:08:37","modified_gmt":"2022-06-06T22:08:37","slug":"aluminum-filler-metals-selection-characteristics-more","status":"publish","type":"post","link":"http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/aluminum-filler-metals-selection-characteristics-more\/","title":{"rendered":"Aluminum Filler Metals: Selection, Characteristics &#038; More"},"content":{"rendered":"<div class=\"m-entry__feedback\"><div class=\"m-feedback-prompt\">\n\t\t  <h4 class=\"m-feedback-prompt__header\">Was this article helpful?<\/h4>\n\t\t  <a href=\"#\" class=\"m-feedback-prompt__button m-feedback-prompt__social m-feedback-prompt__social_thumbsup yes\" data-analytics-link=\"feedback-prompt:yes\">\n\t\t    <i class=\"fa fa-thumbs-up\">&nbsp;<\/i>\n\t\t  <\/a>\n\t\t  <a href=\"#\" class=\"m-feedback-prompt__button m-feedback-prompt_form no\" data-analytics-link=\"feedback-prompt:no\">\n\t\t    <i class=\"fa fa-thumbs-down\">&nbsp;<\/i>\n\t\t  <\/a><br>\n\t\t  <div class=\"m-feedback-prompt__display m-feedback-prompt__social yes\">\n\t\t    <p class=\"m-feedback-prompt__text\">Awesome, share it:<\/p>\n\t\t    <a class=\"m-feedback-prompt__social--button p-button-social has-icon facebook fa fa-facebook\" href=\"https:\/\/www.facebook.com\/sharer\/sharer.php?u=http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/aluminum-filler-metals-selection-characteristics-more\/\" onclick=\"javascript:window.open(this.href,\n  '', 'menubar=no,toolbar=no,resizable=yes,scrollbars=yes,height=600,width=600');return false;\">\n\t\t      <span class=\"p-button-social__social-text\">Share<\/span>\n\t\t    <\/a>\n\t\t    <a class=\"m-feedback-prompt__social--button p-button-social has-icon twitter fa fa-twitter\" href=\"https:\/\/twitter.com\/intent\/tweet?url=http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/aluminum-filler-metals-selection-characteristics-more\/&text=Aluminum Filler Metals: Selection, Characteristics &#038; More\" onclick=\"javascript:window.open(this.href,\n  '', 'menubar=no,toolbar=no,resizable=yes,scrollbars=yes,height=600,width=600');return false;\">\n\t\t      <span class=\"p-button-social__social-text\">Tweet<\/span>\n\t\t    <\/a>\n\t\t    <a class=\"m-feedback-prompt__social--button p-button-social has-icon googleplus fa fa-google-plus\" href=\"https:\/\/plus.google.com\/share?url=http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/aluminum-filler-metals-selection-characteristics-more\/\" onclick=\"javascript:window.open(this.href,\n  '', 'menubar=no,toolbar=no,resizable=yes,scrollbars=yes,height=600,width=600');return false;\">\n\t\t      <span class=\"p-button-social__social-text\">Google Plus<\/span>\n\t\t    <\/a>\n\t\t    <a class=\"m-feedback-prompt__social--button p-button-social has-icon linkedin fa fa-linkedin\" href=\"https:\/\/www.linkedin.com\/shareArticle?mini=true&url=http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/aluminum-filler-metals-selection-characteristics-more\/&title=Aluminum Filler Metals: Selection, Characteristics &#038; More\" onclick=\"javascript:window.open(this.href,\n  '', 'menubar=no,toolbar=no,resizable=yes,scrollbars=yes,height=600,width=600');return false;\">\n\t\t      <span class=\"p-button-social__social-text\">LinkedIn<\/span>\n\t\t    <\/a>\n\t\t  <\/div>\n\t\t  \t<div class=\"m-feedback-prompt__display m-feedback-prompt__form no\">\n\t\t  \t<div class=\"thanks feedback-nodisplayall\"><h2>Thanks!<h2><div class=\"m-contact\"><p>Thanks for getting in touch with us.<\/p><\/div><\/div>\n\t\t    <form id=\"contact-form\" class=\"new_support_request\" action=\"\" accept-charset=\"UTF-8\" method=\"post\">\n\t\t    <input type=\"hidden\" id=\"authenticity_token\" name=\"authenticity_token\" value=\"2585c87b6d\" \/><input type=\"hidden\" name=\"_wp_http_referer\" value=\"\/sandbox\/airgasthinks\/wp-json\/wp\/v2\/posts\/1116\" \/>\n\t\t      <input value=\"http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/aluminum-filler-metals-selection-characteristics-more\/\" type=\"hidden\" name=\"currenturl\" id=\"currenturl\">\n\t\t      <input value=\"Aluminum Filler Metals: Selection, Characteristics &#038; More\" type=\"hidden\" name=\"currenttitle\" id=\"currenttitle\">\n\t\t      <label class=\"is-required\">Help us improve. Give us your feedback:<\/label>\n\t\t      <textarea class=\"p-input__textarea\" name=\"feedbackmessage\" id=\"feedbackmessage\"><\/textarea>\n\t\t      <label class=\"is-required\">Your Full Name:<\/label>\n\t\t      <input class=\"p-input__text\" type=\"text\" name=\"feedbackfullname\" id=\"feedbackfullname\">\n\t\t      <label class=\"is-required\">Your email address:<\/label>\n\t\t      <input class=\"p-input__text\" type=\"text\" name=\"mailinglistemail\" id=\"mailinglistemail\">\n\t\t      <div class=\"feedback-message\" id=\"feedback-message\"><\/div>\n\t\t      <div class=\"__submit\">\n\t\t        <input type=\"submit\" name=\"commit\" value=\"Submit\" class=\"p-button\" id=\"submit-contact-form\" data-analytics-link=\"feedback-prompt:submit\">\n\t\t      <\/div>\n\t\t\t<\/form>\n\t\t\t<\/div>\n\t\t\t<\/div>\n\t\t\t<\/div>\n<p><span style=\"font-weight: 400;\">From its strength and versatility to its corrosion resistance, the benefits of aluminum are appealing for a variety of industries. Welding the material, however, is not without its challenges. Because of its low melting temperature and high thermal conductivity, you must take extra care to prevent burn-through on thinner material and to ensure adequate fusion or penetration on thicker material. Using the appropriate equipment\u2014machines that offer pulsed MIG capabilities or TIG capabilities\u2014is important. So is selecting the right filler metal and understanding the weld characteristics each type provides.<\/span><\/p>\n\n\n\n\n\n<p><span style=\"font-weight: 400;\">There are many aluminum filler metals available in the marketplace, including those for applications found in aerospace or architectural structures to filler metals for heat exchangers, trailer fabrication and more. The filler metals range from pure aluminum to varieties with added copper, silicon or magnesium.<\/span><\/p>\n\n\n\n<p><span style=\"font-weight: 400;\">Among the variety of aluminum filler metals, 4043 and 5356 alloys are the most common and the least expensive. Together, those filler metals are used for welding about 80 percent of the time and are available in wires for MIG welding or cut-lengths (often called filler rods or straight lengths) for TIG welding. You should know how to choose between the two alloys, as well as the characteristics each provide to produce good weld quality. &nbsp;<\/span><\/p>\n\n\n\n<h4><b>Aluminum filler metal characteristics<\/b><\/h4>\n\n\n\n<p><span style=\"font-weight: 400;\">As with any filler metal, 4043 and 5356 aluminum alloys each have unique characteristics. 4043 filler metals tend to have a more fluid weld pool due to the addition of silicon (5 percent), which allows the bead to \u201cwet out\u201d or flow into the base metal more easily. This characteristic produces a more aesthetically pleasing weld, requires less cleanup, reduces leaks and minimizes cracking. <\/span><\/p>\n\n\n\n<p><span style=\"font-weight: 400;\">5356 filler metals contain 5 percent magnesium. As with the silicon in a 4043 product, the addition of this alloying element affects the performance of the filler metal. In this case, the magnesium increases the strength without negatively impacting the toughness of the weld. When welding with 5356 aluminum filler metals, the resulting weld tends to be rippled rather than smooth. Due to the 5 percent magnesium, more smut (black soot) could be present at the edges of the weld that you will need to clean.<\/span><\/p>\n\n\n\n<p><span style=\"font-weight: 400;\">Both 4043 and 5356 filler metals operate with 100 percent argon shielding gas because it provides good arc initiation and stability. Thicker aluminum applications sometimes require helium, which improves heat transfer to the base metal and helps increase weld penetration. Helium can be expensive, though, and the application often sacrifices arc stability when it is added.<\/span><\/p>\n\n\n\n<h4><b>How to make the selection &nbsp;&nbsp;&nbsp;<\/b><\/h4>\n\n\n\n<p><span style=\"font-weight: 400;\">When you select aluminum filler metals, the goal is to choose an alloy that produces a weld that best meets the requirements of the product and its intended use. &nbsp;Sometimes you may want the strongest weld\u2014other times, you may consider leak resistance, ductility, corrosion resistance or toughness to be more important.<\/span><\/p>\n\n\n\n\n\n<p><strong>When you choose between the common 4043 and 5356 aluminum filler metals, there are five important questions to ask:\u2028<\/strong><\/p>\n\n\n\n<ol><li><span style=\"font-weight: 400;\">Will the welded component be exposed to sustained elevated temperature?<\/span><\/li><li><span style=\"font-weight: 400;\">What is the aluminum base designation?<\/span><\/li><li><span style=\"font-weight: 400;\">Will the weldment be subjected to post-weld anodizing?<\/span><\/li><li><span style=\"font-weight: 400;\">Are shear strength, ductility and toughness prime considerations?<\/span><\/li><li><span style=\"font-weight: 400;\">Will post-weld heat treatment be performed?<\/span><\/li><\/ol>\n\n\n\n<p><\/p>\n\n\n\n<p><strong>Providing the base metal is compatible, a 4043 aluminum filler metal will be best for the following:<\/strong><\/p>\n\n\n\n<ul><li><span style=\"font-weight: 400;\">Applications that will be subject to long-term elevated temperature exposure (above 150 degrees Fahrenheit).<\/span><\/li><li><span style=\"font-weight: 400;\">Any application where it is necessary to reduce the risk of termination and shrinkage cracking. <\/span><\/li><li><span style=\"font-weight: 400;\">Instances where aesthetics are particularly important, since these filler metals provide bright, clean welds.<\/span><\/li><li><span style=\"font-weight: 400;\">Situations where distortion is of particular concern, as it minimizes this defect.\u2028<\/span><\/li><\/ul>\n\n\n\n<p><strong>A 5356 aluminum filler metal would be most appropriate for:<\/strong><\/p>\n\n\n\n<ul><li><span style=\"font-weight: 400;\">Welding on 5XXX or 6XXX series of aluminum when tensile strength is most important. <\/span><\/li><li><span style=\"font-weight: 400;\">Achieving good anodized color matching on 5XXX and 6XXX base metals.<\/span><\/li><li><span style=\"font-weight: 400;\">Applications requiring higher ductility and toughness (such as those subject to dynamic loading).<\/span><\/li><li><span style=\"font-weight: 400;\">Applications requiring higher shear strength.<\/span><\/li><\/ul>\n\n\n\n<p><span style=\"font-weight: 400;\">When welding 6XXX series aluminum or 5XXX series aluminum containing less than 3 percent magnesium, you can use either a 4043 or a 5356 filler metal to complete the job. The same holds true for higher shear strength applications; however, it typically takes three fillet passes with a 4043 product to equal the shear strength of one pass using a 5356 filler metal.\u2028<\/span><\/p>\n\n\n\n<h4><b>Proper storage and handling\u2028<\/b><\/h4>\n\n\n\n<p><span style=\"font-weight: 400;\">It is important that you properly store and handle aluminum filler metals. It helps ensure the highest quality welds. Keep the filler metals in a clean, dry area that is of a similar ambient temperature as the weld cell. If you move them from a cold area to a warmer area, it could cause condensation to form on the surface of filler metals and lead to poor weld quality.<\/span><\/p>\n\n\n\n<p><span style=\"font-weight: 400;\">If you aren\u2019t going to use a spool of wire for a while, cover the spool with the plastic bag the wire shipped in or with another protective cover. Store TIG cut-lengths in their original box to protect against dirt and debris.<\/span><\/p>\n\n\n\n<h4><b>Getting the best results<\/b><\/h4>\n\n\n\n<p><span style=\"font-weight: 400;\">In any welding application, your goal is to complete the job with high quality and efficient results. Speed and weld integrity are just as important when you weld aluminum as any other material. Know the basic filler metal characteristics and selection criteria for aluminum to get the best welding performance. Practicing welding this material \u2014 especially for welding operators new to the material \u2014 is also a good idea. Consider welding scrap materials as a starting point to get a firsthand experience of the different operating characteristics of aluminum filler metals. If you need more information about welding aluminum, look for resources with a local welding distributor or filler metal manufacturer. They often have technical support specialists to offer advice.<\/span><\/p>\n\n\n\n<h4><b>Additional<\/b><b> information: equipment considerations<\/b><\/h4>\n\n\n\n<p><span style=\"font-weight: 400;\">In <\/span><span style=\"font-weight: 400;\">addition<\/span><span style=\"font-weight: 400;\"> to proper selection, storage and handling with 4043 and 5356 filler metals\u2014or any aluminum filler metals for that matter\u2014you should have the right welding equipment for the job. This equipment includes:<\/span><\/p>\n\n\n\n<ul><li style=\"font-weight: 400;\"><i><span style=\"font-weight: 400;\">A spool gun or push-pull gun for the MIG welding process<\/span><\/i><span style=\"font-weight: 400;\">. These guns provide consistent feeding of the aluminum filler metals, minimize wire feeding issues and allow for welding further distances from the wire feeder (often as far as 30 feet away).<\/span><\/li><\/ul>\n\n\n\n<ul><li style=\"font-weight: 400;\"><i><span style=\"font-weight: 400;\">U-groove drive rolls<\/span><\/i><span style=\"font-weight: 400;\">. These drive rolls prevent the wire from being pinched or compressed, and they help ensure proper wire feeding.<\/span><\/li><\/ul>\n\n\n\n<ul><li style=\"font-weight: 400;\"><i><span style=\"font-weight: 400;\">Nylon inlet guides and liners<\/span><\/i><span style=\"font-weight: 400;\">. Unlike metal components, nylon components won\u2019t \u201cshave\u201d the wire as it feeds through from the wire feeder to the contact tip, lessening the opportunity for buildup of debris inside the liner.<\/span><\/li><\/ul>\n\n\n\n<ul><li style=\"font-weight: 400;\"><i><span style=\"font-weight: 400;\">Contact tips for aluminum wire. <\/span><\/i><span style=\"font-weight: 400;\">Consumables for aluminum wires typically have an \u201cA\u201d (for aluminum) stamped on them and are sized accordingly for these type of wires. For example, 4043 and 5356 wires are available in 0.047-inch (3\/64-inch) diameters (as opposed to the standard 0.045-inch diameter of steel wires), so the corresponding bore on the contact tip for these wires is slightly oversized, allowing for smooth wire feeding and good arc stability.<\/span><\/li><\/ul>\n\n\n\n<p>More great Airgas Thinks articles related to this topic:<\/p>\n\n\n\n<ul><li><a href=\"http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/mig-gun-selection\/\">Breakdown: How to Select a MIG Gun<\/a><\/li><li><a href=\"http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/troubleshooting-weld-defects-to-save-time-money\/\">Troubleshooting Weld Defects to Save Time &amp; Money<\/a><\/li><li><a href=\"http:\/\/jschaeffer.us\/sandbox\/airgasthinks\/video-robotic-welding-arm-installation\/\">Video: Robotic Welding Arm Installation<\/a><\/li><\/ul>\n","protected":false},"excerpt":{"rendered":"<p>Was this article helpful? &nbsp; &nbsp; Awesome, share it: Share Tweet Google Plus LinkedIn Thanks! 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