Aluminium Welding Guide

ESAB Technical Guide

Aluminium Welding Quality & Filler Metal Selection Guide

Comprehensive specifications, joint configurations, and alloy selection matrix based on official ESAB technical standards (Brochure Pages 6 & 7).

1. Surface Quality & Porosity Elimination

Successful aluminum welding starts with raw material purity. ESAB uses a unique surface shaving process to remove oxide skins and contaminants that cause porosity.

Shaved Wire Surface Eliminates trapped oxides for X-ray quality welds and trouble-free wire feedability.

Hydrogen-Free Lubricant Microscopic coating provides superior feeding through long conduits with reduced fume.

Constant Cast & Helix Guarantees stable arc placement and prevents micro-arcing inside contact tips.

2. Complete Aluminium Filler Metal Selection Table (Pages 6 & 7)

Comprehensive alloy selection reference table covering all 17 base alloy groups, primary/secondary filler recommendations, and performance ratings:

Base Alloy Group	Primary Filler	Secondary Options	W	S	D	C	T	M	Key Metallurgical Notes
[1060] 1060 / 1070 / 1080 / 1350	ER1100	4043	A	D	A	A	A	A	For electrical busbars (1350/1060), use 1100 / 1070 filler wire to preserve conductivity.
[1100] 1100	ER1100	4043	A	D	A	A	A	A	For electrical busbars (1350/1060), use 1100 / 1070 filler wire to preserve conductivity.
[2014] 2014 / 2036	ER4043	5356	A	C	C	B	A	C	General purpose 5% Si filler wire.
[2219] 2219	ER2319	4043	A	A	C	C	B	C	2219 requires 2319 filler for optimal strength after post-weld heat treatment.
[3003] 3003 / ALCLAD 3003	ER1100	4043, 5356	A	C	A	A	A	A	Highest ductility and corrosion resistance.
[3004] 3004	ER4043	5356	A	B	C	B	A	C	Excellent flow and low cracking.
[5005] 5005 / 5050	ER4043	5356	A	C	C	B	A	C	General purpose 5% Si filler wire.
[5052] 5052 / 5652	ER4043	5356	A	C	C	B	A	C	General purpose 5% Si filler wire.
[5083] 5083 / 5456	ER5183	5087, 5356, 5556A	A	A	B	A	C	A	DO NOT use 4043 on 5083 or alloys with >3.0% Mg! High silicon in 4043 combines with Mg to form brittle Mg2Si phase, causing severe cracking.
[5086] 5086 / 5056	ER5183	5087, 5356, 5556A	A	A	B	A	C	A	DO NOT use 4043 on 5083 or alloys with >3.0% Mg! High silicon in 4043 combines with Mg to form brittle Mg2Si phase, causing severe cracking.
[511] 511 / 512 / 513 / 514 / 535 / 5154 / 5254	ER4043	5356	A	C	C	B	A	C	General purpose 5% Si filler wire.
[5454] 5454	ER5554	4043	A	B	B	A	A	A	Alloys with >3.0% Mg (like 5356/5183) are susceptible to stress corrosion cracking if operated above 150°F (65.5°C). Use 5554.
[6005] 6005 / 6063 / 6101 / 6151 / 6201 / 6351 / 6951	ER5356	4043, 5183, 4047	A	B	B	A	C	A	If the weldment is to be anodized after welding, 5356 provides an excellent color match whereas 4043 turns dark gray.
[6061] 6061 / 6070	ER5356	4043, 5183, 4047	A	B	B	A	C	A	If the weldment is to be anodized after welding, 5356 provides an excellent color match whereas 4043 turns dark gray.
[7005] 7005 / 7021 / 7039 / 7046 / 7146 / 710.0 / 711.0	ER4043	5356	A	C	C	B	A	C	General purpose 5% Si filler wire.
[319] 319.0 / 333.0 / 354.0 / 355.0 / C355.0 / 380.0	ER4043	4047	A	B	C	B	A	C	For repairing 356/A356 castings where post-weld heat treatment (T6) is required, use 4043 or 4047.
[413] 413.0 / 443.0 / 444.0 / 356.0 / A356.0 / A357.0 / 359.0	ER4043	4047	A	B	C	B	A	C	For repairing 356/A356 castings where post-weld heat treatment (T6) is required, use 4043 or 4047.

3. Recommended Welding Schedules & Shielding Gas

Shielding Gas Selection Guidelines:

Plate Thickness < 6mm (1/4"): 100% Pure Argon (Flow rate: 14 - 18 L/min)
Plate Thickness 6mm - 12mm (1/2"): Argon + 25% Helium mixture (Flow rate: 18 - 22 L/min)
Plate Thickness > 12mm (1/2"): Argon + 50% to 75% Helium mixture (Flow rate: 22 - 28 L/min)

4. ESAB Marathon Pac™ Bulk Wire Savings

Using 141 kg Jumbo Marathon Pac bulk drums reduces robotic station downtime from 47.6 hours/year down to 2.36 hours/year and drops weld repair rates from 2.0% to 0.10%, yielding up to €8,647.90/year in net operational savings per welding station.