5356 filler wire is lightweight and highly resistant to corrosion. You can use it for aluminum welding, next to 4043 wire, which is ideal for heat-treatable aluminum. Keep reading to discover the properties and sourcing considerations of AA5356 welding alloy.
What is 5356 Aluminum?
5356 aluminum is the most common filler wire for welding 5xxx and 6xxx aluminum. You can rely on AA5356 when welding lightweight yet strong transportation structures. In this section, we discuss the properties of the 5356 aluminum filler material.
5356 Aluminum Composition and Chemical Properties
5356 aluminum falls under the 5xxx aluminum family, and it contains magnesium as its primary alloying element. Other elements are added in tiny amounts, such as iron, manganese, silicon, titanium, and copper.
5356’s AWS designation ER5356 means it is a filler alloy best suited for general-purpose aluminum welding.
Physical and Mechanical Properties
| Physical Property | Average Value |
| Tensile strength | 290 MPa |
| Yield strength | 130 MPa |
| Elongation | 17–26% |
Corrosion resistance properties: Due to its special chemical composition, 5356 aluminum offers exceptional resistance against pollutants and moisture. This is why the marine and industrial communities love 5356 grade of aluminum.
Color after welding (darker appearance): Despite its high welding capacity, 5356 alloy is prone to darkening after welding and anodizing.
Common Forms of 5356 Aluminum
5356 aluminum alloy is typically sold in these forms:
Welding Wire and Filler Rods
5356 aluminum alloy is mostly sold in welding wire, ranging from 0.8 mm to 1.6 mm. Meanwhile, TIG filler rods come in diameters of 1.6 mm to 3.2 mm and lengths of around 1 meter.
Other Product Forms
Apart from welding wire, AA 5356 is sold as sheets and bars. These forms of 5356 aluminum are better suited for the fabrication of other magnesium-based alloys. The standard dimensions of AA5356 sheets and rods vary based on the industry and service environment.
What is 5356 Aluminum Used For?
Aluminum alloy 5356 is widely used in the following applications.
Primary Applications
- Marine fabrication and shipbuilding: 5356 aluminum alloy is typically used for welding marine structures. Your alloy’s corrosion strength is useful in boat hulls, masts, railings, gangways, and offshore structures.
- Structural welding applications: You can also select 5356 aluminum alloy for welded structural applications, such as bridges, storage platforms, and load-bearing supports. The metal exhibits high toughness and tensile strength after welding.
- Automotive and transportation: 5356 is widely used to fabricate bicycle frames, fuel tanks, and railcar components.
- Pressure vessels and tanks: Additionally, you can use AA5356 when welding cryogenic tanks, chemical, or fuel containers. The alloy retains its strength at low temperatures, so it is fit to handle cryogenic conditions without becoming brittle.
Base Metal Compatibility
You are recommended to use 5356 aluminum for welding base metals from the 5xxx series, such as 5052, 5083, and 5456. But, you can also select AA5356 when welding 6061, 6063, and other 6xxx series alloys.
However, if you need to weld cast aluminum or alloys containing silicon, 5356 is not the best option. Instead, use 4043 welding wire or rod.
Industry-Specific Uses
- Aerospace components: In aerospace, 5356 aluminum serves in structural panels and brackets requiring strength and low weight.
- Architectural structures: You can also use AA5356 welding consumables in architectural settings due to their neat weld appearance.
- Heavy equipment: The construction industry relies on AA5356 welding wire for frames and enclosures that withstand stress and vibration.
5356 vs 4043 Aluminum: The Critical Comparison
Here, we compare 5356 to 4043 aluminum alloy.
Key Differences Between 4043 and 5356
The primary difference between 4043 and 5356 alloys of aluminum lies in their chemical composition. 5356 is magnesium-based, so it offers exceptional corrosion strength. 4043, in contrast, is silicon-based, so it is not susceptible to hot cracking at high temperatures.
Furthermore, AA4043 is easier to weld, and it delivers a lighter post-weld color than AA5356. Hence, AA4043 is the superior choice for fabrication jobs where visual appeal is more important than corrosion strength.
When to Use 5356 Aluminum Wire
It is best to select aluminum 5356 welding wire for applications that require high mechanical strength and corrosion resistance. These include marine and transportation components that are exposed to challenging service environments.
When to Use 4043 Aluminum Wire
It is best to use 4043 wire for joining cast aluminum and silicon alloys due to its reduced risk of cracking. 4043 is also ideal for heat-treatable alloys like 6061 aluminum and applications that require more fluidity than 5356 can offer.
Decision-Making Guide
5356 and 4043 aluminum alloys are the top options for high-performance welding wire. If you need help choosing between 4043 and 5356 welding consumables, look at it like this.
AA5356 is the better fit for marine and architectural projects that require high strength and seawater resistance. Meanwhile, AA4043 is the better choice for welding cast aluminum. This is because AA5356’s magnesium content makes it prone to corrosion cracking at temperatures over 150 °C.
Welding with 5356 Aluminum
Tips and best practices for welding with AA5356 consumables.
MIG Welding with 5356 Aluminum
If you are using AA5356 spool to weld thin sheets, maintain a wire speed of 250 inches per minute. For thicker sections of metal, you may go as high as 350 or 400 inches per minute. But never more.
Then, as for amperage, we recommend keeping flow rates between 20 and 30 CFH. Also, it is advisable to use the push technique rather than the pull technique. That way, you can direct the shielding gas over the weld joint and produce brighter beads.
TIG Welding with 5356 Aluminum Rod
In comparison, you can use AA5356 filler rod for TIG welding / TIG fabrication. This method produces clean welds with a sharp surface appearance. But be careful with the heat settings, as excessive temperatures may burn through the surface of your weld.
Additionally, always select a 2% ceriated or lanthanated tungsten electrode and keep the tip slightly rounded to prevent arc wandering.
Pre-Welding Preparation
Before welding any metal, wipe off any oil, grease, or contaminants on your material using acetone. Afterward, brush the joint area with a stainless-steel wire brush dedicated solely to aluminum to remove the oxide film.
It is also recommended to preheat your workpiece to around 150 to 200°F. This action will get rid of any moisture or condensation, preventing weld porosity.
Common Welding Challenges and Solutions
When working with the 5356 welding rod, you may encounter some of these difficulties.
Porosity: Porous welds are caused by trapped hydrogen gases in the metal. To prevent it, store welding consumables in a dry space and clean them thoroughly before any use.
Burn-through on thin materials: As you learned earlier, excessive heat from the welding instrument can burn through your material. The best way to prevent this is to stay within safe operating temperatures for the aluminum grade you are welding.
Distortion control techniques: Aluminum expands significantly when you heat it. This is why it is vital to tack-weld your material before completing the final weld joint. This helps reduce internal pressure as the metal cools.
Achieving proper penetration: To ensure the weld penetrates deep enough, we recommend welding with a push angle of 10 to 15 degrees. You should also adjust the voltage and current based on the thickness of your workpiece.
Quality Considerations
When evaluating AA5356 samples, ensure that they carry the AWS A5.10 certification. This certification sets the bar for marine-grade alloys. Furthermore, conduct tensile and composition tests to ensure that the samples offer consistent properties with AA5356 datasheets.
Technical Specifications and Standards
This section reveals technical standards to check when sourcing 5356 welding wire.
Industry Standards
Before purchasing AA 5356, ensure it complies with the AWS A5.10 specifications. Another detail to check is the ASME Section II requirements. This protocol ensures your welding wire is fit to withstand demanding industrial environments.
Quality Assurance
When verifying the quality of 5356 filler metal, begin with a chemical analysis. This helps you confirm that elements such as magnesium, manganese, and chromium are alloyed within the specified composition ranges.
Following the chemical analysis, perform mechanical tests to evaluate the tensile strength and elongation of your 5356 sample. You can then compare the results against AA 5356 datasheets to spot any shortcomings.
Storage, Handling, and Safety
Here are the best practices for handling and storing 5356 welding wire.
Proper Storage Methods
To prevent porosity in your welds, store 5356 filler rod in a clean, sealed container. We also suggest regularly checking your spools for any signs of contamination.
Safety Considerations
Always weld aluminum in a large and well-ventilated area. Additionally, ensure that all factory personnel wear the appropriate personal protective equipment (PPE), including flame-resistant clothing, gloves, and eyewear.
Cost Considerations and Purchasing Guide
Typically, 5356 aluminum wire costs more than its 4043 counterpart due to the higher cost of magnesium. However, prices can also vary depending on factors such as spool size, brand, and the quantity of spools ordered.
When choosing suppliers, it’s best to work with those that have a solid reputation for providing products that meet quality standards.
Conclusion
5356 aluminum filler wire offers excellent strength and corrosion resistance. It is the best selection for welding non-heat-treatable aluminum. If you must heat treat your application before service, it is better to use 4043 aluminum filler wire.
FAQs
Can 5356 aluminum filler wire be used for underwater welding applications?
Yes. 5356 aluminum is the most popular filler rod for marine welding. This alloy offers exceptional mechanical strength and resistance to seawater attack. The only downside is that 5356 cannot withstand prolonged service above 150 °C. In that case, use 4043 filler rod.
Does 5356 aluminum wire require special storage conditions compared to other filler metals?
Yes. We recommend cleaning your 5356 filler wire, then storing it in an airtight container. This is the best way to prevent contaminants from touching the surface of your filler rod. As you learned earlier, moisture or dirt on aluminum surfaces can cause porosity during welding.
Can you mix 5356 and 4043 aluminum wire in the same weld joint?
No. We do not recommend mixing 5356 and 4043 filler alloys in the same weld joint.
What is the maximum thickness that can be welded with 5356 aluminum in a single pass?
On average, you can weld up to 6mm of 5356 aluminum wire in a single pass. However, this number varies based on the thickness of your joint. Thick sections, for instance, usually require more passes for a thorough penetration.
Is 5356 aluminum wire compatible with flux-core welding processes?
No. 5356 aluminum filler rod is best suited for MIG and TIG welding.
How do 5356 aluminum welds perform at elevated temperatures?
When heated above 150 °C, your 5356 filler rod loses ductility and becomes prone to cracking. If you’re building high-temperature appliances, it is better to use 4043 aluminum rod.
Can 5356 aluminum be used to repair cracked aluminum castings?
No. It is not recommended to use 5356 filler alloy to repair cracked aluminum castings. Due to your alloy’s high magnesium content, the metals won’t fuse properly. Furthermore, the weld joint will be prone to cracking.
What is the typical shelf life of 5356 aluminum welding wire once opened?
If stored in a clean, dry, and sealed environment, opened spools can last indefinitely. However, exposure to moisture or contaminants can cause your AA5356 wires to degrade rapidly.
Does 5356 aluminum wire work with spool gun MIG welding systems?
Yes. 5356 is a good selection for spool gun MIG systems. It is even recommended when working with thicker aluminum sections because it feeds smoothly and maintains consistent arc stability.
Can you use 5356 aluminum for welding dissimilar metals (aluminum to steel or stainless)?
No. You can not use a 5356 aluminum filler rod to weld steels and other dissimilar metals. The reason is that aluminum does not bond properly to ferrous metals. When needed, it is best to use bimetallic welding joints or special transition inserts.
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