Aluminium is known for its versatility and corrosion resistance but it also has unique challenges for welders. In short, achieving successful MIG welding of aluminium relies on several factors, with the choice of welding wire being vital. In this article, we’ll go into the types of aluminium welding wires and their impact on achieving flawless welds.

Understanding Welding Wire:

Welding wire serves as a filler metal in wire welding processes like MIG welding and Flux Core welding. Generally these can be divided into solid and flux core wires. Solid wires are used in MIG welding, requiring an external shielding gas, while flux-cored wires contain flux to shield the weld. When it comes to aluminium welding, we should focus on the types, differences, and specific requirements. For a more in-depth guide on MIG wires look at our MIG Welding Wire Types. 

MIG Welding with Aluminum Wire:

MIG welding aluminium is beginner-friendly compared to TIG welding, making it a choice option for hobbyists. However, choosing the right aluminium filler metal is crucial. Both ER4043 and ER5356 has been popular choices for MIG welding on various aluminium alloys.

ER4043 MIG Aluminum Welding Wire:

ER 4043 is a general-purpose aluminium welding wire that is widely used for welding alloys. They are especially found in common applications like bicycles, trucks, and automotive parts. What’s more, it has 5% silicon additives. Therefore, it offers improved fluidity of the weld pool, allowing for spray transfer and reduced sensitivity to cracking.

ER5356 MIG Welding Aluminum Wire:

ER5356 is another general-purpose aluminium wire with 5% magnesium additives. This enhances weldability and provides high shear strength. The ER5356 is ideal for welding thick materials. Plus, it offers excellent corrosion resistance, making it suitable for applications exposed to saltwater.

ER4043 vs. ER5356 – What Works Best for You?

When comparing ER4043 and ER5356 you should considering factor such as additives, weld puddle fluidity, service temperatures, colour match, tensile strength, shear strength, and softness. Each wire has its advantages, and the choice depends on specific welding requirements.

Welding Equipment for Aluminium Wires:

Aluminium filler metal’s unique properties require special welding equipment to ensure smooth wire feed. Equipment such as spool guns and graphene liners are recommended accessories to prevent interruptions, clogging, or bird nests during the welding process.

MIG Welder for Aluminum:

Choosing a MIG welder that supports spool guns or high wire feed speed is crucial for aluminium welding. Features such as compatibility and wire feed capabilities are essential for achieving quality welds on aluminium alloys.

MIG Welding Parameters for Aluminium Wires:

Provided are typical MIG welding parameters for both ER4043 and ER5356 wires, including wire diameter, wire feed speed, amperage, volts, wire consumption, and argon gas flow rates.

Flux Core Welding Aluminum – Possibilities and Challenges:

While theoretically possible, flux core welding for aluminium is not commercially viable due to challenges in flux composition, corrosiveness, and environmental impact. On the whole, Flux core aluminium welding wires, if available, lack standardised specifications and are not recommended for reliable results.

Final Thoughts:

Choosing the right welding wire is essential for successful aluminium welding. Both ER4043 and ER5356 are popular choices for hobbyists, offering good results on a range of aluminium alloys. Despite the challenges posed by aluminium wire feedability, investing in specialised equipment is a cost-effective solution compared to TIG welding. Mastering aluminium welding requires understanding the nuances of welding wire selection and equipment compatibility for achieving flawless welds.

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