Aluminum Welding Wire Selection Chart by Base Metal

How to pick an aluminum wire

Selecting an aluminum wire depends on more than the base-metal grade; several factors must be weighed together: the alloy family of the base metal, the strength the joint requires, the corrosion resistance demanded by the service environment (particularly seawater and damp outdoor conditions), the long-term service temperature, whether anodizing is required and how closely the color must match, and welding suitability — namely crack resistance, weld-pool fluidity and operating tolerance. With these properly matched, the result is a well-formed and durable weld.

The chart below sets out the recommended filler and available substitutes for each common base metal, for day-to-day reference. It is compiled per AWS A5.10 and common industry practice, but does not replace a welding procedure written for your specific part, equipment and acceptance requirements. Actual welding should be governed by your own WPS.

If the weld already shows porosity or similar defects, see the separate guide to aluminum weld porosity, which includes a symptom-cause-action chart and pre-weld cleaning practice.

Base metal to filler chart

The Recommended column gives the filler most often specified for each base metal or combination; Alternative lists fillers that the AWS A5.10 guide or major filler producers also allow, with the trade-off in Notes. Dissimilar joints are listed at the end.

Base metal	Recommended	Alternative	Notes
1xxx (1100)	ER1100	ER4043, ER4047	Pure aluminum; ER4043 or ER4047 only where electrical conductivity is not a primary requirement. Conductor grades 1060 / 1070 / 1350 are listed with ER1188.
2219	ER2319	ER4145	Heat-treatable Al-Cu; ER2319 is the dedicated filler, and ER4145 may also be used per the AWS A5.10 guide.
3003	ER1100	ER4043, ER4047	The AWS A5.10 guide groups 3003 with 1100; filler producers also note that 3xxx alloys weld readily with ER4043 or ER5356.
3004	ER5356	ER4043	The AWS guide lists ER5356 first; some manufacturer charts list ER4043, so both are in use.
5005 / 5052	ER5356	ER4043	Mg-bearing base; 5356 matches better. Do not weld 5052 with a matching-composition filler: it is crack-sensitive.
5754	ER5356	ER5183, ER5754 (AlMg3)	European alloy, not in the AWS table; Mg above 2.5%, so no ER4043. ER5183 where higher strength is needed; matching AlMg3 where color match or corrosion resistance comes first.
5083	ER5183	ER5356, ER5556	Where a 40 ksi (276 MPa) minimum weld tensile is specified, use ER5183 or ER5556; ER5356 often falls short.
5086	ER5356	ER5183, ER5556	Good corrosion resistance in seawater.
5454	ER5554	ER5356, ER5183	ER5554 is the matching filler. For sustained service above about 65°C use ER5554; ER5356 and ER5183 are not recommended for that duty and suit service below it.
6061 / 6063 / 6082 / 6005A (6xxx)	ER4043	ER5356	Never weld without filler (hot-crack sensitive). 4043 for lower crack sensitivity; 5356 for shear strength, ductility, feeding and anodized color match. 6082 / 6005A per European practice.
7005 (also 7004, 7039)	ER5356	ER5183, ER5556	Weldable 7xxx; most other 7xxx alloys are not considered arc-weldable. 7005 to 5083: ER5183.
Castings 356.0 / A356.0 / 357.0	ER4043	ER4047	4047 flows better: narrower melting range, less shrinkage and hot cracking.
Castings 319.0 / 355.0 / C355.0 (Cu-bearing)	ER4145	ER4043, ER4047 for some applications	The AWS guide lists ER4145 for these Al-Si-Cu castings.
6xxx to 5xxx (>2.5% Mg: 5083, 5086, 5456, 5154)	ER5356	ER5183, ER5556	ER4043 not recommended: Si and Mg form brittle Mg₂Si. ER5183 where 5083 strength governs.
6xxx to 5005 / 5052	ER4043 (5005); ER5356 (5052)	ER5356 (5005); ER4043 (5052, some applications)	Lower-Mg 5xxx; ER4043 remains acceptable.
6xxx to 1xxx / 3xxx	ER4043	ER4047; ER5356 (to 3004)	Per the AWS A5.10 guide.
6xxx to 3xx.x castings	ER4043	ER4047	Si-based filler per the AWS A5.10 guide (6061 to 356.0) and filler producers.
5xxx to 356-type castings	ER4043 (5005, 5052); ER5356 (5083, 5086, 5456)	—	Follow the Mg level of the 5xxx side.

TGM keeps ER4043 / 4047 / 5356 / 5183 / 5554 in stock — the full line held in inventory with reliable supply; other grades (e.g. ER1100, ER2319) available on request.

Compiled per AWS A5.10 and common industry practice; specifics governed by your WPS.

Classification cross-reference

Drawings, purchase orders and procedure records name the same wire in different systems: an AWS A5.10 classification in some specifications, an EN ISO 18273 designation in others, and an ASME Section IX F-number on the WPS and PQR. The table maps the five grades TGM stocks across all three. A change of F-number is an essential variable for procedure qualification, so moving from an F-22 filler such as ER5356 to an F-23 filler such as ER4043 needs a new PQR; a change within F-22 does not by itself, provided base-metal compatibility, required strength and the other essential variables are still met.

Grade	AWS A5.10	EN ISO 18273	ASME IX F-number	Alloy type (AWS A5.10 Mg or Si range)
ER4043	ER4043	S Al 4043 (AlSi5) or S Al 4043A (AlSi5(A))	F-23	Al-Si, 4.5–6.0% Si
ER4047	ER4047	S Al 4047 (AlSi12) or S Al 4047A (AlSi12(A))	F-23	Al-Si, 11–13% Si
ER5356	ER5356	S Al 5356 (AlMg5Cr(A))	F-22	Al-Mg, 4.5–5.5% Mg
ER5183	ER5183	S Al 5183 (AlMg4,5Mn0,7(A))	F-22	Al-Mg-Mn, 4.3–5.2% Mg
ER5554	ER5554	S Al 5554 (AlMg2,7Mn)	F-22	Al-Mg-Mn, 2.4–3.0% Mg

For ER4043 and ER4047, EN ISO 18273 has a variant with and without the "A" suffix; the one that applies to a given lot is the one stated on its mill certificate. Confirm F-number groupings against the Section IX edition specified for your contract.

What to weigh when choosing

Strength: where higher joint strength is required, choose the Mg-bearing 5xxx fillers (5356 / 5183), which deliver greater strength than 4043; for high-strength bases such as 5083, 5183 is the first choice.
Corrosion and seawater service: for parts in marine environments or seawater contact, the Mg-bearing 5xxx fillers (5356 / 5183 / 5554) are preferred, offering better corrosion resistance than the Si-based 4043.
Service temperature: where long-term service exceeds 65°C, avoid the high-Mg fillers (5356 / 5183) to prevent intergranular corrosion; ER5554 is recommended instead.
Anodizing: where the part is anodized and color consistency matters, 5356 anodizes to a lighter tone that harmonizes with most base metals, whereas 4043 tends to anodize gray and dark.
Welding suitability: the higher silicon in 4043 gives good weld-pool fluidity, broad operating tolerance and low hot-cracking tendency, making it well suited to 6xxx, castings and dissimilar joints; 4047 flows even better and is commonly used for brazing and repair.

Three selection rules

Base metal above about 2.5% Mg → Al-Mg filler, not ER4043. This covers 5083, 5086, 5456, 5154 and 5754, and 6xxx joined to them. Use ER5356 or ER5183: silicon from ER4043 combines with the magnesium to form brittle Mg₂Si, which lowers weld ductility and toughness.
Sustained service above about 65°C → ER5554 on 5454. Per the AWS A5.10 guide and filler manufacturers, alloys and fillers with more than about 3% Mg are not recommended for this duty because they can become sensitized, so the base metal matters as much as the wire: 5454 is the highest-Mg 5xxx alloy suited to this duty, and ER5554 (2.4–3.0% Mg) is its matching filler.
Anodized or visible welds → ER5356. Al-Si fillers turn gray to dark gray after anodizing, and ER4047 gray-black, leaving a visible weld line; ER5356 anodizes close to 5xxx and 6xxx base metal.

Castings: 356.0 / A356.0 / 357.0 take ER4043, or ER4047 where more fluidity and less shrinkage help; ER4047 melts over about 577–582°C against about 574–632°C for ER4043. Cu-bearing castings such as 319.0 and 355.0 are listed with ER4145 in the AWS guide.

Selection by application

Each application page covers the base metals, joint types and welding notes for that sector; the usual grades are summarized here.

5083 · 5086 · 5454

Pressure vessels & tanks

ER5183 where strength governs, ER5356 for general service, ER5554 on 5454 for sustained duty above 65°C.

View application → 6xxx extrusion · 5xxx plate

Rail car bodies

ER4043 for general 6xxx extrusion work, ER5356 for 5xxx structures and anodized parts, ER5183 for 5083 plate.

View application → Hulls · LNG tanks

Marine & LNG

ER5183 and ER5356 for hulls and superstructures; 5083 LNG tanks are widely welded with ER5183.

View application → 6xxx trays

EV battery trays

ER4043 for 6xxx sealing seams, ER5356 for load-bearing joints and 5xxx plate.

View application → Enclosures · hot tanks

Energy & storage

ER5356 for enclosures, ER5183 for load-bearing parts, ER5554 with 5454 where service runs above 65°C.

View application → 5052 · 5754 · 5083

Reefer & insulated bodies

ER5356 for 5052 / 5754 panels, ER5183 for underframes, door frames and more demanding areas.

View application →

Grade datasheets

Open each grade for its chemical composition, mechanical properties and typical applications, to support an accurate selection.

Al-Si all-rounder

ER4043

The most widely used general-purpose wire, suited to 6xxx, castings and dissimilar joints, with good weld-pool fluidity, low hot-cracking tendency and broad welding suitability.

Learn more → High-Si / braze

ER4047

Higher silicon content gives particularly good fluidity, suited to brazing, repair and joints with demanding seal-tightness requirements.

Learn more → Al-Mg workhorse

ER5356

The most widely used Mg wire, balancing joint strength and corrosion resistance, and anodizing to a lighter tone for easier color matching.

Learn more → High-strength marine

ER5183

Matched to high-strength bases such as 5083, with high joint strength, suited to shipbuilding and pressure vessels.

Learn more → High-temp

ER5554

A lower-Mg formulation that resists intergranular corrosion in long-term service above 65°C, suited to parts operating at elevated temperatures.

Learn more →

Shipping from overseas? The document set, how C/O Form E works and what makes it fail, tariff classification and lead-time planning are covered in the import guide.

Frequently asked questions

Which aluminum welding wire should I use?

Start from the base metal. For 6xxx extrusions such as 6061, 6063 and 6082, use ER4043 or ER5356; for 5083, ER5183; for 5086 and most other 5xxx alloys, ER5356; for 5454 in sustained service above about 65°C, ER5554; for 356-type castings, ER4043 or ER4047. On 5xxx base metals above about 2.5% Mg, use an Al-Mg filler rather than ER4043. Confirm the final choice in your WPS.

What filler should I use to weld 6061 to 5083?

Use an Al-Mg filler. The AWS A5.10 guide lists ER5356 for 6061 to 5083, and ER5183 or ER5556 may also be used, with ER5183 the usual choice where the strength of 5083 governs. Do not use ER4043: 5083 contains well above 2.5% Mg, and silicon from the filler combines with the magnesium to form brittle Mg2Si, which lowers weld ductility and toughness.

Is ER4043 or ER5356 better for 6061?

Both are accepted; the AWS A5.10 guide lists ER4043 first, with ER5356 as an alternative. ER4043 gives a more fluid pool and lower hot-crack sensitivity, which helps on restrained or high-dilution joints. ER5356 gives higher shear strength and ductility, feeds better and anodizes to a much closer color match. Either way, 6061 should not be welded without filler, because it is hot-crack sensitive.

What is the EN ISO 18273 equivalent of ER5356?

ER5356 corresponds to S Al 5356 (AlMg5Cr(A)) under EN ISO 18273. The other common grades map as follows: ER5183 = S Al 5183 (AlMg4,5Mn0,7(A)), ER5554 = S Al 5554 (AlMg2,7Mn), ER4043 = S Al 4043 (AlSi5) or 4043A (AlSi5(A)), and ER4047 = S Al 4047 (AlSi12) or 4047A (AlSi12(A)). For the Al-Si grades, the variant that applies is the one stated on the mill certificate.

Which aluminum filler should I use for service above 65°C?

Use ER5554 on 5454 base metal. Alloys and fillers with more than about 3% Mg, including ER5356 and ER5183, are not recommended for sustained service above about 65°C (150°F): Mg-rich beta phase precipitates along grain boundaries and makes the weld susceptible to intergranular corrosion and stress-corrosion cracking. ER5554 contains 2.4–3.0% Mg and is the matching filler for 5454, per the AWS A5.10 guide and filler manufacturers' guidance.

Questions on selection? Contact our technical team

Provide the base-metal grade, joint type and service environment, and our technical team will help determine the appropriate grade, advise on WPS direction, and where required provide on-site welding training and technical support, together with a quotation.

Get a quote →

Aluminum Welding Wire Selection Guide