Storage
Keep wire sealed in a dry store at steady temperature. Return part-used spools to their bags with desiccant; moisture on the wire is a main cause of porosity.
Welding consumables guide
ER5183 and ER5356 Welding Wire for Aluminium Tankers
ER5183 and ER5356 are the two aluminium-magnesium fillers used for almost every seam on a 5xxx aluminium tank truck. ER5183 gives the higher weld strength and is the standard match for 5083 shells; ER5356 is the general-purpose choice for 5182, 5754 and lower-stressed joints. Metline supplies both to AWS A5.10 and EN ISO 18273 as MIG spools and TIG rods, with certificates, to tanker builders worldwide.
- Classifications
- ER5183 · ER5356
- Standards
- AWS A5.10 · EN ISO 18273
- MIG wire
- 0.8 – 1.6 mm spools
- TIG rod
- 1.6 – 5.0 mm × 1000 mm
Choosing filler for a 5xxx tanker
Tank shells, heads and baffles are built from high-magnesium alloys such as 5083, 5182, 5454 and 5754. These alloys must be welded with a 5xxx filler: silicon-based 4xxx fillers form brittle magnesium silicide in the weld and are not acceptable on base metals with more than about 2.5 % magnesium.
Within the 5xxx fillers, the choice comes down to strength and service temperature. ER5183 contains extra manganese (0.50 – 1.0 %) and gives the highest as-welded strength of the common fillers, enough to match 5083-O. ER5356 has slightly more magnesium but little manganese, with titanium for grain refinement; it is easier to buy, very widely qualified and strong enough for most other tank seams.
Neither filler suits hot cargo. Both contain about 5 % magnesium and, like the base metals, can become sensitised in long service above roughly 65 °C. Bitumen and heated-chemical tankers built in 5454 should use ER5554 filler instead.
ER5183 and ER5356 chemical composition (wt %)
| Element | ER5183 | ER5356 |
|---|---|---|
| Magnesium (Mg) | 4.3 – 5.2 | 4.5 – 5.5 |
| Manganese (Mn) | 0.50 – 1.0 | 0.05 – 0.20 |
| Chromium (Cr) | 0.05 – 0.25 | 0.05 – 0.20 |
| Titanium (Ti) | 0.15 max | 0.06 – 0.20 |
| Silicon (Si) | 0.40 max | 0.25 max |
| Iron (Fe) | 0.40 max | 0.40 max |
| Copper (Cu) | 0.10 max | 0.10 max |
| Zinc (Zn) | 0.25 max | 0.10 max |
| Beryllium (Be) | 0.0003 max | 0.0003 max |
| Others, each / total | 0.05 / 0.15 | 0.05 / 0.15 |
| Aluminium (Al) | Remainder | Remainder |
Limits per AWS A5.10/A5.10M. EN ISO 18273 equivalents: S Al 5183 (AlMg4.5Mn0.7(A)) and S Al 5356 (AlMg5Cr(A)).
Weld strength and physical data
Filler wire classifications do not set tensile requirements; weld strength is proven by procedure qualification on the actual base metal. Typical published figures are shown below.
| Property | ER5183 | ER5356 |
|---|---|---|
| Typical all-weld-metal tensile | about 275 – 300 MPa | about 250 – 290 MPa |
| Fillet weld shear, longitudinal (typical) | ≈ 128 MPa (18.5 ksi) | ≈ 117 MPa (17 ksi) |
| Fillet weld shear, transverse (typical) | ≈ 193 MPa (28 ksi) | ≈ 179 MPa (26 ksi) |
| Groove weld in 5083-O, min. tensile (qualification codes) | 275 MPa (40 ksi) | lower; check code |
| Melting range | about 579 – 638 °C | about 571 – 635 °C |
| Density | 2.66 g/cm³ | 2.64 g/cm³ |
| Colour after anodising | White to light grey | White |
Shear values are commonly published fillet-weld data for aluminium fillers; design values must come from the applicable code (for example AWS D1.2, EN 1999 or the tank design standard).
Filler selection by tanker base metal
| Base metal | Recommended filler | Alternative | Notes |
|---|---|---|---|
| 5083 shell, heads | ER5183 | ER5356 for low-stress welds | 5183 matches 5083-O strength |
| 5182 shell, heads | ER5356 | ER5183 | Use 5183 for highest-stressed seams |
| 5754 shell | ER5356 | ER5183 | Both give strong, corrosion-resistant welds |
| 5454 hot-cargo shell | ER5554 | ER5356 only for ambient service | Avoid 5183/5356 for service above 65 °C |
| 6061 / 6063 tubes to 5xxx | ER5356 | — | 4043 is not suitable when joined to high-Mg alloys |
| Cast fittings (Al-Si) | ER4043 | — | Only where neither part is a high-Mg alloy |
Wire forms, sizes and packing
| Form | Diameters | Packaging |
|---|---|---|
| MIG spool wire | 0.8, 0.9, 1.0, 1.2, 1.6 mm | 0.45 – 0.5 kg (100 mm spool), 2 – 2.5 kg (200 mm), 6 – 7 kg (300 mm) and larger |
| TIG straight rod | 1.6, 2.0, 2.4, 3.0, 3.2, 4.0, 5.0 mm | 1000 mm lengths (36 in on request) in 2.5, 5 or 10 kg tubes |
| Bulk drums | 1.0 – 1.6 mm | For robotic welding of long shell seams |
Diameter tolerance on MIG wire is tight (typically within a few hundredths of a millimetre) so that it feeds smoothly through push-pull and robotic systems. Specify spool type (plastic or wire basket) to match your feeder.
Good practice on tanker seams
Feeding
5183 and 5356 are stiff enough for push feeders at short lengths; use U-groove rolls, PTFE or nylon liners and push-pull guns for long cables.
Cleaning
Degrease, then stainless-brush the joint just before welding. Do not use brushes that have touched steel.
Shielding
Pure argon is standard; argon-helium mixes increase penetration on thick sections and fast robotic seams.
Heat input
Control heat input and interpass temperature to limit distortion and the softened zone; preheat is not normally needed on 5xxx.
Inspection
Penetrant, radiographic or ultrasonic testing of shell seams as the tank code requires.
What to check when buying
- ClassificationER5183 or ER5356 to AWS A5.10, or S Al 5183 / S Al 5356 to EN ISO 18273, matching your qualified welding procedure.
- Form and sizeDiameter, spool size and type, or rod length and pack weight.
- CertificateLot certificate with chemical analysis; EN 10204 3.1 on request.
- PackingSealed, moisture-proof packs with clear lot labelling for traceability.
References and standards
- AWS A5.10/A5.10M – Welding Consumables: Wires and Rods for Aluminum and Aluminum-Alloys
- EN ISO 18273 – Welding consumables: wire electrodes, wires and rods for welding of aluminium and aluminium alloys
- AWS D1.2/D1.2M – Structural Welding Code: Aluminum
- EN 14286 – Weldable rolled products for tanks for the storage and transportation of dangerous goods
ER5183 and ER5356 for tankers: FAQ
Is ER5183 or ER5356 better for a 5083 tanker?
ER5183. Its extra manganese gives weld metal strong enough to match 5083-O, which is what welding codes assume when qualifying 5083 joints. ER5356 can be used on lower-stressed attachments.
Can I use ER4043 on a tank shell?
No. On high-magnesium alloys such as 5083, 5182 and 5454, silicon fillers form brittle Mg2Si and the welds can crack. Use a 5xxx filler.
Which filler for a hot bitumen tanker?
For 5454 tanks carrying cargo above about 65 °C, use ER5554. ER5183 and ER5356 contain about 5 % magnesium and can become sensitised in hot service.
What sizes are used for tanker MIG welding?
Most shell seams are welded with 1.2 mm or 1.6 mm wire; 1.0 mm is common for thinner parts and positional welding.
Do ER5183 and ER5356 aluminum welds need post-weld heat treatment?
No. Both fillers and the 5xxx base metals are non-heat-treatable; welds reach full strength as welded.
Need ER5183 or ER5356 for tank fabrication?
Send the classification, diameter, pack form and quantity. We will confirm availability and certification.
