which rods do you guys use/recommend for aluminum.

im using the 4043 rods and the finished beads doesnt look smooth like most on here. it has specks all over. i dont think its my welding, because heres welding from two different rods welded the same way.

unknown rod i used (brought home from where i used to work)


4043 rod


its kind of hard to see, but the first bead is pretty smooth. i dont know, maybe it is my welding, but can any confirm if there is a better rod to use then 4043.

 

were they done with different welders/ setups? the first one looks like it was done with a gas lense where the second one does not. the oxidization pattern around the weld on the first one is very consistent and narrow where on the second one it is wide and all over the place...

 

both welds were done by me.

the first one came when i had first got the machine, and i was still learning how to weld. i didnt have a gas lense at the time. these were scrap pipes and filler brought home by my brother for me to practice on.

the second one is of a recent weld. and i do have a gas lense now. no matter what i do i cant seem to get the nice smooth beads. i know its not the greatest bead as an example but all of my aluminum welds have thhose specks now.

who knows it might just be me. i just wanted to see if anyone experience different output form different rods.

 

here i'll write a book on it

designation of alloy groups

1xxx- pure 99% and greater
2xxx-copper (not weldable)
3xxx-maganese
4xxx-silicon
5xxx-magnesium
6xxx-magnesium and silicon
7xxx-zinc (not weldable due to zinc melts at 400 degrees)
8xxx-other elements

ok those are the different series of them

filler metals that are needed you can find specifics in the cliff notes of the filler metal that you can get usually. They are very helpful

1xxx-must be welded with a 1000 series filler
2xxx-considered mostly non weldable (most shops will not attempt it)
3xxx-used largely for casting applications. Must match filler material. 4000 series usually
4xxx-weldable
5xxx-weldable
6xxx-weldable but may need heat treating afterwards
7xxx-considered unweldable
8xxx-weldable depending on alloy, must heat treat afterwards

Heat treatable aluminums are as follows
2xxx,6xxx,7xxx series aluminums.
These are considered non fusable, and must use a matching filler metal to weld them to prevent cracking. Lower amperage and faster travel speeds are needed as well.

Non heat treatable aluminums are
1xxx,3xxx,4xxx,5xxx series. and these also gain strength from cold working them. These can be welded with or without filler metal.

Sorry about the book, but i hope this puts some insight on welding aluminum. Sometimes i dont think people realize how technical welding can be, and how they can mess something up very bad if they dont know what they are doing. Especially when it comes to welding stainless, and aluminum alloys.

 

Nice thread. I also use 4043 and get those same results with the little crevises/pores in the puddle. I have never used any other rod on aluminum so I cant really help you there, but if someone has the answer please share it!
No offense to jay, but that made NO sense to me! LOL I think it all just went over my head...more explanation please?!
Kyle

 

I have used both 4043 and 5356 on various grades of aluminum. It seems as though the 4043 is more used but I personally have had better success with the 5356. I dont really know why but my welds always come out looking alot nicer when using the 5356 ? Not to say that the weld is any stronger but definately nicer looking.

 

4043 rod leaves those bumps, 5356 doesnt. its alot smoother and stronger.

 

I don't like 4043 for anything that has to look good.

 

me= welding geek. I was just trying to show what metals are weldable, and just because its aluminum does not mean you can go and just weld anything with an aluminum filler rod. And even if you get the right filler rod, it may need to be heat treated afterwards. Sorry if i got too specific. If there is anything you would like the specifics on let me know. I will try my best to explain it.

 

Thanks a bunch Jay, and to the other who chimed in after me(not to hijack the thread). Jay, now that I know what I am looking at, it defenitely makes more sense. Seems I will be buying some 5356 next time Im at the welding shop! Thanks again!
Kyle

 

no problem. Always do your research before you go welding away. It will save you a lot of headaches in the long run.