Cryogenic propellant tanks
Fusion welds and repairs in 2219 tanks for liquid oxygen and liquid hydrogen on launch vehicles.
Aerospace filler metal
2319 Aluminium Welding Wire & Filler Rod
2319 is the matching filler metal for welding 2219 aluminium, the high-copper alloy used in launch-vehicle tanks and hot-running airframe structure. It is classified as ER2319 / R2319 under AWS A5.10 and supplied to AMS 4191 for aerospace work. Metline supplies 2319 MIG spools and TIG cut lengths with full certification to customers worldwide.
- Classification
- ER2319 / R2319
- Standards
- AWS A5.10 · AMS 4191 · ISO 18273
- Base metal
- 2219, 2014, 2024 repairs
- Forms
- MIG spools, TIG rods
What 2319 filler wire does
Most high-strength 2xxx and 7xxx alloys crack when fusion welded, because the weld solidifies over a wide temperature range and tears as it shrinks. 2219 is an exception, and 2319 is the filler that makes the most of it: its chemistry is essentially that of 2219 with extra titanium, so the weld bead can be heat-treated with the parent metal and responds in the same way.
The titanium (0.10 – 0.20 %) and zirconium (0.10 – 0.25 %) act as grain refiners in the weld pool. A finer, equiaxed weld structure resists hot cracking and gives better ductility than a coarse columnar one. Magnesium is held to a very low level, because even small amounts in an aluminium-copper weld widen the freezing range and raise crack sensitivity.
The result is a filler that gives higher weld strength in 2219 than the general-purpose 4043 silicon filler, especially when the welded part is solution treated and aged after welding. That is why it is specified for cryogenic propellant tanks, pressure vessels and hot structures built from 2219 sheet, plate, extrusions and forgings.
2319 chemical composition (wt %)
Limits below follow the AWS A5.10 / ISO 18273 classification (S Al 2319, AlCu6MnZrTi). The certificate for each lot reports the actual analysis. Note that a simple list of "typical" percentages, such as Cu 6.3 %, is a nominal figure, not a specification limit.
| Element | Limit | Purpose in the weld |
|---|---|---|
| Copper (Cu) | 5.8 – 6.8 | Matches 2219; provides heat-treatable strength |
| Manganese (Mn) | 0.20 – 0.40 | Strength and grain control |
| Titanium (Ti) | 0.10 – 0.20 | Grain refiner in the weld pool; higher than in 2219 |
| Zirconium (Zr) | 0.10 – 0.25 | Grain refinement and crack resistance |
| Vanadium (V) | 0.05 – 0.15 | Elevated-temperature strength |
| Silicon (Si) | 0.20 max | Impurity |
| Iron (Fe) | 0.30 max | Impurity |
| Magnesium (Mg) | 0.02 max | Kept low to limit hot cracking |
| Zinc (Zn) | 0.10 max | Impurity |
| Beryllium (Be) | 0.0003 max | Limited for welder health |
| Others each / total | 0.05 / 0.15 | |
| Aluminium | Remainder |
Physical data and weld performance
Filler metal data
- Density
- about 2.84 g/cm³
- Melting range
- about 543 – 643 °C
- Electrical conductivity
- about 30 % IACS
- Colour match after anodising
- Good on 2219; slightly darker than 4043 welds
Weld strength is a property of the joint, not of the wire. It depends on the base metal and temper, joint design, process, heat input and whether the assembly is heat-treated afterwards. For that reason AWS A5.10 classifies filler by chemistry and AMS 4191 adds aerospace controls on composition, cleanliness, dimensions and packaging, while joint strength is qualified through your welding procedure (for example under AWS D17.1 for aerospace fusion welding).
As a guide, 2219 joints welded with 2319 and left as-welded develop roughly the strength of the solution-treated, naturally aged parent metal in the heat-affected zone. Re-solution treating and ageing the complete weldment recovers a large part of the T8 strength. Weld ductility is markedly better than with 4043, and toughness at cryogenic temperature is good.
Earlier data sheets quoted "tensile ≥ 450 MPa, yield ≥ 370 MPa" for 2319 wire. Those values describe neither a filler classification nor a typical 2219 weld and should not be used for design.
2319 wire sizes and packaging
| Form | Common diameters | Packaging |
|---|---|---|
| MIG (GMAW) wire | 0.8, 1.0, 1.2, 1.6 mm (0.030, 0.035, 3/64, 1/16 in) | Precision-layer-wound spools, 0.5 – 7 kg, sealed with desiccant |
| TIG (GTAW) rod | 1.6, 2.4, 3.2, 4.0 mm (1/16, 3/32, 1/8, 5/32 in) | 914 mm (36 in) cut lengths in sealed tubes or cartons |
| Larger rod / wire | up to about 12 mm | Coils or straight lengths for special processes |
| Electron-beam / laser wire | to process requirement | Small spools, cleanliness-controlled |
Each spool or tube is labelled with the classification, diameter, lot number and specification. Aerospace orders are traceable from the certificate to the cast and drawing lot.
Good practice when welding 2219 with 2319
- Clean the jointDegrease, then remove the oxide by stainless-steel brushing or chemical etching shortly before welding. Copper-bearing alloys are prone to porosity from hydrated oxide.
- Keep the wire dry and cleanStore spools sealed, in a heated cabinet if humidity is high. Contaminated wire is the most common cause of weld porosity.
- Use the right shieldingPure argon for TIG on thin sections; argon-helium mixtures improve penetration on thick plate and MIG welding.
- Control heat inputUse the lowest heat input that gives full fusion, to limit the width of the softened heat-affected zone.
- Plan heat treatmentDecide in advance whether the part stays as-welded or is re-solution treated and aged; the welding procedure and allowables depend on it.
- InspectRadiography, dye penetrant and, for tanks, leak and proof testing are typical acceptance steps.
Where 2319 is used
Hot structures
Welded 2219 frames, ducts and brackets in engine bays and high-speed airframes.
Pressure vessels
Aerospace and ground-support pressure vessels where high joint ductility is required.
Missile and defence
Welded 2219 casings and structures that see heat and vibration.
Repair welding
Approved repairs on 2219 parts; occasionally specified for 2014 and 2024 repairs under engineering approval.
Additive manufacturing
Wire-arc additive manufacturing research and production of 2219-type parts uses 2319-chemistry wire.
2319 compared with 4043 and 4145 fillers
| Factor | 2319 | 4043 | 4145 |
|---|---|---|---|
| Main alloying | Cu 6.3 %, Ti, Zr, V | Si 5 % | Si 10 %, Cu 4 % |
| Best for | 2219 welds needing strength and ductility | General 6xxx and cast-alloy welding | Crack-sensitive 2xxx repairs, brazing |
| Responds to post-weld heat treatment | Yes, like 2219 | Limited | Limited |
| Weld ductility on 2219 | High | Low | Low |
| Hot-crack resistance | Good on 2219 | Very good | Excellent |
4043 is easier to weld with and more forgiving of fit-up, but the silicon-rich weld is brittle on 2219 and does not age-harden with it. For qualified aerospace 2219 work, 2319 is the standard choice.
How to order 2319 wire
- SpecifyClassification (ER2319 or R2319), specification (AWS A5.10, AMS 4191, EN ISO 18273), diameter and form.
- PackagingSpool type and weight, or TIG rod length and pack size; any cleanliness or sealed-pack requirements.
- Quote and termsWe confirm availability, certification and delivery on EXW, FOB, CIF or DAP terms.
- CertificationCertificate of conformity and EN 10204 3.1 lot analysis; traceability to cast lot.
References and standards
- AWS A5.10/A5.10M – Welding Consumables: Wires and Rods for Welding of Aluminum and Aluminum Alloys
- SAE AMS 4191 – Aluminum Alloy Welding Wire, 2319
- EN ISO 18273 – Wire electrodes, wires and rods for welding of aluminium and aluminium alloys
- AWS D17.1 – Specification for Fusion Welding for Aerospace Applications
- The Aluminum Association – Welding Aluminum: Theory and Practice
2319 aluminium (aluminum) welding wire: FAQ
What is 2319 welding wire used for?
It is the matching filler for welding 2219 aluminium, mainly in aerospace tanks, pressure vessels and hot structures. It gives better weld strength and ductility on 2219 than 4043 and responds to post-weld heat treatment.
Is 2319 the same as 2219?
Almost. 2319 has the same copper, manganese, zirconium and vanadium ranges as 2219 but more titanium (0.10 – 0.20 %) to refine the weld grain and reduce hot cracking.
Which specification covers 2319 for aerospace?
AWS A5.10 classifies it as ER2319 (wire) and R2319 (rod); AMS 4191 is the aerospace material specification. EN ISO 18273 lists it as S Al 2319 (AlCu6MnZrTi).
Can 2319 be used to weld 6061 or 5083?
No. It is designed for 2219. Use 4043 or 5356 for 6xxx alloys and 5183 or 5556 for 5xxx alloys.
Why do 2219 welds show porosity?
Usually hydrogen from moisture or hydrated oxide on the joint or wire. Clean the joint immediately before welding, keep wire sealed and dry, and check shielding gas quality.
What diameters of 2319 wire are available?
MIG wire is commonly 0.8 – 1.6 mm and TIG rod 1.6 – 4.0 mm in 914 mm lengths; other sizes up to about 12 mm can be supplied on request.
Welding 2219? Order matching 2319 filler
Send the form, diameter, quantity and specification. We reply with availability, certification and freight to your site.
