Drive rolls
Use U-groove rolls sized to the wire with light, even tension; knurled V-rolls shave the wire and clog the liner.
Welding consumables guide
ER5356 Aluminium Welding Wire
ER5356 is the general-purpose aluminium MIG wire: a 5 % magnesium filler that gives strong, ductile, corrosion-resistant welds on 5xxx and 6xxx alloys and feeds reliably through standard equipment. It is the most widely used aluminium filler in boatbuilding, trailers, truck bodies and tanks. Metline supplies ER5356 to AWS A5.10 / ASME SFA-5.10 on spools from 0.8 to 1.6 mm, plus matching TIG rod, worldwide.
- Classification
- ER5356 (AWS A5.10)
- ISO
- S Al 5356 (AlMg5Cr(A))
- MIG sizes
- 0.8 – 1.6 mm
- Spools
- 0.5 – 7 kg and larger
Why ER5356 is the default aluminium MIG wire
Aluminium MIG welding needs a wire that is strong enough for structural joints, stiff enough to push through a liner without tangling, and compatible with the widest range of base metals. ER5356 ticks all three boxes, which is why it outsells every other aluminium filler for gas metal arc welding.
Its magnesium content gives about 1.5 – 1.7 times the fillet shear strength of ER4043, and the welds stay ductile and resistant to seawater. Chromium and titanium refine the grain and reduce crack sensitivity. Because 5356 wire is noticeably stiffer than 4043, it feeds well through push-type guns over moderate cable lengths, as well as through push-pull and robotic systems.
Two limits apply. 5356 should not be used for parts that run above about 65 °C for long periods, and it is not suitable for high-silicon casting alloys. For those cases 4043, 4943 or 5554 are better choices.
Wire forms, sizes and packaging
| Diameter | Process | Packaging options | Approx. wire length per kg |
|---|---|---|---|
| 0.8 mm (0.030 in) | MIG | 0.5 kg (100 mm) and 2 kg (200 mm) spools | ≈ 750 m |
| 0.9 mm (0.035 in) | MIG | 0.5 kg, 2 kg and 7 kg spools | ≈ 600 m |
| 1.0 mm (0.040 in) | MIG | 2 kg, 6 – 7 kg spools | ≈ 480 m |
| 1.2 mm (3/64 in) | MIG / TIG | 6 – 7 kg spools, 1000 mm rods | ≈ 330 m |
| 1.6 mm (1/16 in) | MIG / TIG | 6 – 7 kg spools, drums, 1000 mm rods | ≈ 190 m |
| 2.4 – 4.0 mm | TIG | Straight rods, 36 in or 1000 mm, 2.5 – 10 kg tubes | — |
Length per kg is calculated from a density of 2.64 g/cm³ and rounded. Spool weights vary with spool type.
Large drums suit robotic cells and long production runs; they reduce changeovers and the waste of part-used spool ends.
Chemical composition and physical data
| Element | Limit (%) |
|---|---|
| Magnesium (Mg) | 4.5 – 5.5 |
| Manganese (Mn) | 0.05 – 0.20 |
| Chromium (Cr) | 0.05 – 0.20 |
| Titanium (Ti) | 0.06 – 0.20 |
| Silicon (Si) | 0.25 max |
| Iron (Fe) | 0.40 max |
| Copper (Cu) | 0.10 max |
| Zinc (Zn) | 0.10 max |
| Beryllium (Be) | 0.0003 max |
| Others, each / total | 0.05 / 0.15 |
| Aluminium (Al) | Remainder |
Physical data
- Solidus / liquidus
- about 571 °C / 635 °C (1060 / 1175 °F)
- Density
- 2.64 g/cm³ (0.095 lb/in³)
- Electrical conductivity
- about 29 % IACS
- Thermal conductivity
- about 115 – 120 W/m·K
- Typical all-weld-metal tensile
- about 250 – 290 MPa (36 – 42 ksi)
- Colour after anodising
- White
Starting MIG parameters for ER5356
Aluminium is usually MIG welded with DC electrode positive (DCEP) in spray or pulsed-spray transfer. The ranges below are indicative starting points from published welding charts for flat-position work with argon; qualify your own procedure for the joint, position and equipment.
| Wire diameter | Current (A) | Voltage (V) | Typical plate thickness | Argon flow |
|---|---|---|---|---|
| 0.8 mm (0.030 in) | 60 – 175 | 15 – 24 | 1.5 – 3 mm | 12 – 14 L/min |
| 0.9 mm (0.035 in) | 70 – 185 | 15 – 27 | 2 – 5 mm | 14 – 17 L/min |
| 1.2 mm (3/64 in) | 125 – 260 | 20 – 29 | 4 – 10 mm | 17 – 21 L/min |
| 1.6 mm (1/16 in) | 170 – 300 | 24 – 30 | 8 mm and above | 21 – 26 L/min |
Pulsed MIG extends spray-like transfer to thin sheet and positional welding at lower average current. Argon-helium blends (25 – 75 % helium) raise penetration and travel speed on plate above about 10 mm.
Feeding aluminium wire reliably
Liner
PTFE, nylon or carbon-PTFE liners, as short and straight as possible. Replace liners regularly.
Contact tip
Aluminium tips are slightly oversized to allow for thermal expansion; replace when the bore wears oval.
Gun type
Push guns work for 5356 up to about 3 m cables; spool guns or push-pull for longer reach or 0.8 mm wire.
Spool brake
Set the hub brake just enough to stop overrun; too much drag causes birdnesting.
Technique
Push the gun at 10 – 15° and keep a consistent stick-out; dragging aluminium causes porosity and soot.
Base metal compatibility
| Base metal | Use ER5356? | Comment |
|---|---|---|
| 5005, 5050, 5052, 5754 | Yes, recommended | Strong, ductile, colour-matched welds |
| 5083, 5086, 5456 | Yes | ER5183 or ER5556 for highest strength |
| 5454 | Ambient service only | ER5554 for service above 65 °C |
| 6061, 6063, 6082 | Yes, recommended | Higher strength than 4043; control dilution and heat input |
| Al-Si castings (A356) | No | Use ER4043 or ER4047 |
| 7xxx structural alloys | Case by case | ER5356 or ER5556 for weldable 7005 / 7020; not for 7075 |
Common defects and how to prevent them
| Defect | Likely cause | Prevention |
|---|---|---|
| Porosity | Hydrogen from moisture, oil or hydrated oxide; poor gas coverage | Clean and brush joints, store wire dry, check gas flow and leaks |
| Hot cracking | High dilution of 6xxx base metal, concave craters | Add more filler, use correct joint prep, fill craters |
| Lack of fusion | Low heat input, wrong gun angle, cold start | Raise current, push the gun, use hot start or run-on tabs |
| Black soot | Magnesium oxide from 5xxx filler | Improve shielding, shorten arc, brush after welding |
| Burnback and birdnesting | Feeding problems | Correct rolls, liner, tip and brake settings |
ER5356 compared with other aluminium fillers
| Filler | Strength | Anodised colour | Hot-crack resistance | Service above 65 °C | Typical use |
|---|---|---|---|---|---|
| ER5356 | Medium–high | White | Good | No | 5xxx and 6xxx general fabrication |
| ER4043 | Medium | Dark grey | Very good | Yes | 6xxx, castings, warm service |
| ER5183 | High | White–grey | Good | No | 5083 and other high-strength 5xxx |
| ER5556 | High | White–grey | Good | No | High-strength 5xxx and weldable 7xxx |
| ER5554 | Medium | White | Good | Yes | 5454 for hot service |
See the 4043 vs 5356 comparison for choosing between the two most common fillers.
Where ER5356 wire is used
- Boats and ships: hulls, decks and superstructures in 5083, 5086 and 6061
- Trailers and truck bodies: frames, floors, side walls and tippers
- Tanks and vessels: fuel, water and process tanks in 5xxx alloys
- Architecture: railings, canopies and anodised frames
- Equipment and sports goods: bicycle frames, ladders, machine guards
References and standards
- AWS A5.10/A5.10M – Welding Consumables: Wires and Rods for Aluminum and Aluminum-Alloys
- ASME BPVC Section II Part C – SFA-5.10
- EN ISO 18273 – Wire electrodes, wires and rods for welding of aluminium and aluminium alloys
- AWS D1.2/D1.2M – Structural Welding Code: Aluminum
ER5356 aluminium (aluminum) welding wire: FAQ
Which aluminium alloys can ER5356 weld?
It is the standard filler for 5xxx alloys such as 5052, 5083 and 5754 and is widely used on 6061, 6063 and 6082. It is not suitable for high-silicon castings.
What is the difference between ER5356 and ER4043?
ER5356 gives stronger, more ductile welds that anodise white; ER4043 flows more easily, is less crack-sensitive and suits castings and warm service but turns dark grey when anodised.
Do I need a spool gun for ER5356?
Not always. ER5356 is stiff enough to push through a short gun with a PTFE liner and U-groove rolls. For 0.8 mm wire or cables longer than about 3 m, use a spool gun or push-pull system.
What shielding gas should I use?
Pure argon for most work; argon-helium mixes for thick plate or faster travel. Never use CO₂ or argon-CO₂ mixes on aluminium.
How should ER5356 wire be stored?
Keep spools sealed in a dry place at steady temperature and return part-used spools to their bags. Moisture on the wire causes porosity.
Is the wire certified?
Yes. ER5356 is supplied to AWS A5.10 / ASME SFA-5.10 with lot certificates; EN 10204 3.1 documents can be provided on request.
Need ER5356 welding wire?
Send the diameter, spool type, quantity and destination. We will confirm availability, certification and a delivered price.
