AlcoTec Aluminum

Technical Guide

Contents

AlcoTec Aluminum Wire & Equipment Technical Guide

Table of Contents
Environmental Health and Safety.......................................................................................................................................... 3
Technical Services
Heat Treatable & Non-Heat Treatable Base & Fillers.............................................................................................................. 6
Filler Alloys: Chemical Composition Limits & Physical Properties .......................................................................................... 7
Conversion Factors ............................................................................................................................................................. 7
Welded Joint Strength.......................................................................................................................................................... 8
Typical Tensile Properties - Groove Welds............................................................................................................................. 9
Weld Profiles....................................................................................................................................................................... 10
Weld Control Characteristics.............................................................................................................................................. 11
Parameter Changes & Current Density............................................................................................................................... 11
Backing Bars...................................................................................................................................................................... 12
Bend Testing Aluminum...................................................................................................................................................... 13
Atmospheric Conditions Affect Weld Quality....................................................................................................................... 14
Feedability.......................................................................................................................................................................... 15
Excessive Face Reinforcement........................................................................................................................................... 16
Dilution............................................................................................................................................................................... 17
Aluminum Alloys................................................................................................................................................................. 18
Heat-Treatable and Non Heat-Treatable Alloys & the Heat Affected Zone (HAZ).................................................................. 19
Considerations When Repairing Aluminum Structures........................................................................................................ 20
Shielding Gas for Arc Welding Aluminum............................................................................................................................ 21
Easy Weld Quality Tests...................................................................................................................................................... 22
Weld Cracking.................................................................................................................................................................... 24
Performance Improvement - Increasing Wire Diameter....................................................................................................... 26
Filler Alloy for Welding 6061-T6........................................................................................................................................... 27
The Affect of Texture on Anodizing...................................................................................................................................... 28
Recommended Welding Parameters.................................................................................................................................. 29
Aluminum Filler Alloy Chart................................................................................................................................................. 30
Education
Welder Certification and Qualification.................................................................................................................................. 34
AlcoTec School of Aluminum Welding Technology.............................................................................................................. 35
AlcoTec School of Aluminum Welding Technology Course Outline...................................................................................... 36
Classroom.......................................................................................................................................................................... 36
Laboratory.......................................................................................................................................................................... 36

Our mission: To provide our customers with the most cost-effective solutions for their welding and
cutting applications. Through technological leadership, the most reliable products and deliveries, and continuous
improvement of our processes, we will delight our customers, employees, shareholders, and community.

Our values: Integrity, Progress, Quality, Leadership, and Teamwork.

The AlcoTec advantage.

At AlcoTec , aluminum welding isnt just part of our business, its our only business.

Since 1984, AlcoTec aluminum wire has been world renowned for quality, consistency,
and performance.
And premium aluminum wire is just the start of what we offer. Our goal is to help

We take the concerns

of our customers to heart.
Todd Peters, Operations Manager, AlcoTec Wire Corporation

you work smarter, faster, and better. With continuous innovation, we maximize your
productivity while minimizing your costs by:

Providing service and support that goes the extra mile to keep you up and running

Helping you take your aluminum welding skills to the next level through expert training

Becoming the ultimate partner you can trust for years to come

At AlcoTec, integrity is just as important to us as the quality of our product.

We strive to treat everyone with the utmost respect. We measure our
success by the number of long-term customers who trust us and
value what we bring to the table. And we appreciate it when
our customers say how much they like working with us.
We invite you to get to know AlcoTecs products,
equipment, and technical services.

Environmental Health and Safety

At AlcoTec, we put a heavy emphasis on environmental health and safety, and are constantly looking for ways
to improve our operations. Our facilities and products meet or exceed all applicable governmental requirements
and standards. We educate and encourage our employees to comply with EHS policies.
AlcoTec is a subsidiary of ESAB Group, Inc., - the first global company to achieve
both ISO 14001 (1999) and OHSAS 18001 (2006) certifications. Furthermore, we are
proud to be ISO 9001 certified.

Technical Services

Technical Services
No one knows aluminum welding better.
We are your tried and true aluminum welding experts. Unlike other manufacturers who deal with multiple
welding processes, we specialize solely in aluminum. This allows us to provide an unmatched array of services
from experienced engineers and technicians - expertise you wont find anywhere else.
As an AlcoTec partner, help is always available. Our Customer Service Specialists work directly from our
manufacturing facility, so youll work with a factory-based technician who can help you with everything from
troubleshooting to checking on the status of an order. You can even arrange a consultation with one of our
industry-leading Metallurgical or Welding Engineers.
Our team of Field Specialists have been technically trained to personally solve simple problems to complex
issues. You can reach our Service Team by phone, email, Facebook, or our website. Either way, you can
look forward to a prompt, thorough response to your question.

I absolutely recommend
AlcoTec. Theyre more than
a wire company. They fix
issues that arent really
their problems.
Rusty Beckner, AlcoTec customer

Get the most from your application

As a specialized process, there are many factors to consider when
welding aluminum that will determine the effectiveness of your application.
This section details some of the more critical technical specifications that
will help you get the most from your aluminum welding application.

Technical Services

Technical Services

Heat Treatable & Non-Heat Treatable Base & Fillers

Filler Alloys: Chemical Composition Limits & Physical Properties

Alloy

Silicon

Iron

Copper

Si

Fe

Cu

Aluminum Alloy Designation Tree

1100

Manganese Magnesium Chromium Zinc

Si + Fe = 0.95 0.05-0.20

Titanium

Others (1)

Aluminum

Approximate
Density
Melting Range,
lbs/in3
F

Post (4)
Anodize
Color Tint

Mn

Mg

Cr

Ti

Each

Total

Al (min)

0.05

0.10

0.05

0.15

99.00

1190-1215

.098

Golden

0.03

0.01

0.01

99.88

1215-1220

.0975

Clear

1188

0.06

0.06

0.005

0.01

0.01

1199

0.006

0.006

0.006

0.002

0.006

0.006

0.002

0.002

99.99

1220

.0975

Clear

1350

0.10

0.40

0.05

0.01

0.01

0.05

0.03

0.10

99.50

1195-1215

.0975

Clear

206.0

0.10

0.15

4.2-5.0

0.20-0.50

0.15-0.35

0.10

0.15-0.30

0.05 (2)

0.15

Rmnd

1060-1200

.101

Golden

2319

0.20

0.30

5.8-6.8

0.20-0.40

0.02

0.10

0.10-0.20

0.05 (3)

0.15

Rmnd

1010-1190

.100

Golden

357.0

6.5-7.5

0.15

0.05

0.03

0.45-0.6

0.05

0.20

0.05

0.15

Rmnd

1040-1140

.098

Gray

4008

6.5-7.5

0.09

0.05

0.05

0.30-0.45

0.05

0.04-0.15

0.05

0.15

Rmnd

1035-1135

.097

Gray

4009

4.5-5.5

0.20

1.0-1.5

0.10

0.45-0.6

0.10

0.20

0.05

0.15

Rmnd

1015-1150

.098

Gray

4010

6.5-7.5

0.20

0.20

0.10

0.30-0.45

0.10

0.20

0.05

0.15

Rmnd

1035-1135

.097

Gray

4043

4.5-6.0

0.8

0.30

0.05

0.05

0.10

0.20

0.05

0.15

Rmnd

1065-1170

.097

Gray

4047 11.0-13.0

0.8

0.30

0.15

0.10

0.20

0.05

0.15

Rmnd

1070-1080

.096

Gray-Black

4145

9.3-10.7

0.8

3.3-4.7

0.15

0.15

0.15

0.20

0.05

0.15

Rmnd

970-1085

.099

Gray-Black

4643

3.6-4.6

0.8

0.10

0.05

0.10-0.30

0.10

0.15

0.05

0.15

Rmnd

1065-1175

.097

Gray

5183

0.40

0.40

0.10

0.50-1.0

4.3-5.2

0.05-0.25

0.25

0.15

0.05

0.15

Rmnd

1075-1180

.096

White

5356

0.25

0.40

0.10

0.05-0.20

4.5-5.5

0.05-0.20

0.10

0.06-0.20

0.05

0.15

Rmnd

1060-1175

.096

White

5554

0.25

0.40

0.10

0.50-1.0

2.4-3.0

0.05-0.20

0.25

0.05-0.20

0.05

0.15

Rmnd

1115-1195

.097

White

5556

0.25

0.40

0.10

0.50-1.0

4.7-5.5

0.05-0.20

0.25

0.05-0.20

0.05

0.15

Rmnd

1065-1175

.096

White

5654 Si + Fe = 0.45

0.05

0.01

3.1-3.9

0.15-0.35

0.20

0.05-0.15

0.05

0.15

Rmnd

1100-1190

.096

White

5087

0.25

0.40

0.05

0.7-1.1

4.5-5.2

0.05-0.25

0.25

0.15

0.05 (5)

0.15

Rmnd

1054-1180

.096

White

5754

0.40

0.40

0.10

0.50

2.6-3.6

0.30

0.20

0.15

0.15 (6)

0.15

Rmnd

1095-1195

.097

White

(1) Berylium shall not exceed 0.0003%

(2) Nickel shall not exceed 0.05%
(3) Vanadium shall be 0.05-0.15% and Zirconium shall be 0.10-0.25%

(4) Use filler alloy chart for color matching

(5) 0.10-0.20 Zr
(6) 0.10-0.6 Mn + Cr

Conversion Factors
Fraction

Decimal

mm

ft/lb.

m/kg

Approximate
Wire Gauge

Convert From

Convert To

Multiply By

.030

0.8

1215

816

20.5

inches

millimeters

25.4

.035

0.9

900

605

19

millimeters

inches

.03937

.040

1.0

704

473

18

square inches

square millimeters

645.2

3/64

.047

1.2

520

349

17

square millimeters

square inches

.001552

1/16

.062

1.6

290

195

14

fluid ounces

millimeters

29.57

.071

1.8

220

150

13

millimeters

fluid ounces

.03381

The Aluminum Association uses a four digit numbering system for designating wrought aluminum and wrought aluminum alloys.
The image above shows the wrought alloy groups as well as a few examples of common products from each group.
The significance of each number is described below.

.079

2.0

172

115

12

ounces

grams

28.35

3/32

.093

2.4

130

87

11

grams

ounces

.03527

1st Digit Identifies the major alloying element.

1/8

.125

3.2

70

47

pounds

kilograms

.4536

5/32

.156

4.0

45

30

6.5

kilograms

pounds

2.205

2nd Digit Identifies the rendition of an alloy. For example, 5356 is the 3rd rendition of the original base alloy 5056.

3/16

.187

4.7

31

21

4.5

Newtons/mm

pounds/inch

145.04

3rd and 4th Digits:

1/4

.250

6.3

20

13

pounds/inch

Newtons/mm

.006895

In the 1XXX group, the last two digits indicate the minimum aluminum percentage. For example, alloy 1188
has a minimum purity of 99.88% aluminum. Alloy 1350 has a minimum purity of 99.50% aluminum.
In the 2XXX 8XXX groups, the last two digits serve merely as counters. For example, 3004 was the next
manganese alloyed chemistry after 3003.
6

Technical Services

Technical Services

Welded Joint Strength

Typical Tensile Properties - Groove Welds

Typically, the as-welded tensile strength of a groove weld is determined by the condition of the heat-affected zone (HAZ)
of the base material.

Base Alloy Properties

Fillet welds are usually not diluted significantly by the base metal. Therefore, the shear strengths of fillet welds are largely
determined by the properties of the filler alloy and not necessarily by the condition of the HAZ of the base.

Base
Approximate
Alloy
Melting Range
& Temper F of Base Alloy

Typical Shear Strength - Fillet Welds

Filler Alloy

Longitudinal Shear Strength (KSI)

Transverse Shear Strength

(KSI)

1100

7.5

7.5

2319

16.0

18.8

4043

11.5

15.0

4643

13.5

20.0

5183

18.5

28.0

5356

17.0

26.0

5554

15.0

23.0

5556

20.0

30.0

5654

12.0

18.0

Conservative values based on bare minimum fusion. Multiple factors influence shear strength. Contact AlcoTec to discuss your specific application.

Longitudinal Fillet Weld

15000

2000

5654




5556

1000

5000

5356

20000

Load

3000
15000

4643
5554
5654

10000

5356
5556

1/4
3/8
1/2
Longitudinal fillet - size, in.

1000

Tensile
Yield
Tensile
Yield
Strength Strength
Strength Strength
psi x 103 psi x 103 Elongation psi x 103 psi x 103 Elongation
(1)
(1)
(2)
% in 2 in.
(2)
% in 2 in.

1060-H16

1195-1215

16

15

ER1188

10

29

1100-H16

1190-1215

21

20

ER1100

13

29

1350-H16

1195-1215

18

16

ER1188

10

29

3003-H34

1190-1210

35

29

ER1100

16

24

5005-H16

1170-1210

26

25

ER5356

16

15

5050-H34

1155-1205

28

24

ER5356

23

12

18

5052-H32

1125-1200

33

28

12

ER5356

28

14

19

5083-H116

1075-1180

46

33

16

ER5183

43

22

16

5086-H34

1085-1185

47

37

10

ER5356

39

19

17

5154-H34

1100-1190

42

33

13

ER5654

33

18

17

5454-H32

1115-1195

39

30

15

ER5554

35

16

17

5456-H112

1055-1180

45

24

22

ER5556

46

23

14

2014-T6

945-1180

70

60

13

ER4043

34

28

50

2219-T81

1010-1190

66

50

10

ER2319

35

26

43 (3)

37 (3) (4)

2 (3) (4)

6061-T4

1080-1205

35

21

22

ER4043

27

18

35 (3) (4)

8 (3) (4)

6061-T6

1080-1205

45

40

12

ER4043

27

18

44 (4)

40

6061-T6

1080-1205

45

40

12

ER5356

30

19

11

(1) Reduced section tensile strength.

(2) 0.2% offset in 2 in. gauge length.
(3) Postweld aged only.
(4) Data assumes sufficient dilution of base.

1/8

4043

5000

4043

2000

Filler
Alloy

Post-Weld Heat Treated & Aged

Typical properties of gas-shielded, arc welded groove joints in aluminum alloys.

4000

1100

1100

19.0

Shear strength, kg. per linear cm

3000

10000

15.9

4000

Load

4643
5554

25000

Fillet Size (mm)

9.5
12.7

20000

6.4

3.2

Shear strength, lb. per linear in.

1 1/2 in. (Ends of weld

machined)

19.0

15.9

Fillet Size (mm)

9.5
12.7

Shear strength, lb. per linear in.

25000

6.4

Shear strength, kg. per linear cm

3.2

Transverse Fillet Weld

Tensile
Yield
Strength Strength
psi x 103 psi x 103 Elongation
(1)
(2)
% in 2 in.

As Welded Properties

5/8

3/4

1/8

1/4
3/8
1/2
Transverse fillet - size, in.

5/8

3/4

Technical Services

Technical Services

Weld Control Characteristics

Weld Profiles
Acceptable Weld Profile Criteria per AWS D1.2

Recommendations

Max Reinforcement
3/32
1/8
3/16

Width of Weld Face

5/16
>5/16 to <1
1

Max Convexity
1/16
1/8
3/16

Weld Profile Troubleshooting Guide

Problem

Example (Groove Weld)

Possible Solution

Root Pass

Shorter Arc

Finish Pass

Longer Arc

5XXX Alloys

Shorter Arc
Lower Arc Voltage
Higher Amperage

4XXX Alloys

Longer Arc
Higher Arc Voltage
Lower Amperage

High

Short

Long

Excessive Convexity/
Reinforcement
Reduced fatigue strength

Example (Fillet Weld)

Low

Base Thickness
T 3/8
3/8 < T 3/4
T > 3/4

Penetration (Amperage)

Arc Length (Voltage)

Increase arc length

Increase torch angle
Increase travel speed

Parameter Changes & Current Density

Change torch angle
Change torch position1

Increasing arc voltage decreases:

Wire to work piece gap

Undercut
Reduced mechanical
properties

Change torch position

to compensate for:
Dissimilar section sizes
Dissimilar thermal conductivity
Out-of-position welds

Overlap
Severe reduction
in fatigue strength

Increase voltage
Decrease wire speed
Increase travel speed

Incomplete Penetration/
Lack of Fusion
Reduced weld strength
and increased sensitivity
to crack propagation

Increase amperage
Decrease arc length
Decrease torch forehand angle
Increase travel speed

(1) For example, the thermal conductivity of 5083 is 32% less than that of 6061 because of the higher magnesium content. This requires more heat input
into the 6061 alloy.

Energy distribution width

20V x 150A = 3 kW

23V x 131A = 3 kW

0.32

88 kJ/in2 sec

0.43

Reduce cooling rate

Increase electrode feed rate
Decrease travel speed
Decrease arc length

Insufficient Throat/Underfill
Reduced mechanical
properties

N/A

Insufficient Leg Length

Reduced mechanical
properties

77 kJ/in2 sec

Increasing arc voltage reduces arc energy concentration

.047 in. wire diameter = (.0235 in.)2 x = .0017 in.2 section

10

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Technical Services

Technical Services

Backing Bars

Bend Testing Aluminum

What is the best backing bar material for an aluminum groove weld?

When conducting bend tests, care must be taken to ensure the proper bending criteria are used. The following steps
should be taken to help ensure accurate bend test results.

There really isnt a best material for a backing bar. To determine the most appropriate material, you must
consider a few things:

1. Ensure proper test jig is used:

Is the backing bar going to be permanent or temporary?

Material Thickness

For a permanent backing bar the answer is easy use the same alloy as one of the groove weld components.
For temporary bars, consider these points:
Hard-coat anodized aluminum, copper, stainless steel, and ceramic can all be used.

Bend Mandrel Diameter

Dont weld directly on the backing material. A temporary bar is there only to support the root reinforcement.
Elements from the backing material may contaminate the weld.
Hard-coat anodized aluminum works very well. The thermal properties are the same as the base material
and the groove is easily machined.
Copper has a tendency to cool the weld more quickly than the other materials (copper cools quickly).
Stainless Steel has a tendency to heat up and cool the weld more slowly (stainless cools slowly).
Ceramic is available with adhesive for attaching directly to the base material, but is also very fragile.

Wrap-Around Guided Bend Jig

(Preferred for Aluminum)

Should the groove be square or rounded in a temporary backing bar?

Typically, a square cut groove is going to provide better results than a rounded (or bowl shaped) groove.
The images below show the result of a square cut in the temporary backing bar, the joint design, and the cross
section of the weld achieved.

Plunger-Style Test Jig

(Not Recommended for Aluminum)

2. Review applicable code/specification to ensure the proper bend radius is used. Also note that this is where the base
and filler alloy combination affects the bend radius and sample thickness.
Excerpt from AWS D1.2: 2014

0.25

0.06


60



0.04




Thickness of Specimen

Bend Mandrel Diameter

Materials

3/8
t

1-1/2
4t

M21 and M22

1/8
t (<1/8)

2-1/16
16-1/2t

M23* or F23 Welds

3/8
t

2-1/2
6-2/3t

M25 and Annealed M23*

*Note: Temper condition can also have an influence on the testing criteria.

3. Ensure samples are prepared properly, according to the applicable code/specification, prior to bending.

0.25

1 Pass - 1.6 mm 5356 - approximately 22 ipm travel speed

23.0 V; 342 ipm wire feed speed

Proper

Improper

Sanding lines should be perpendicular to the weld

(in-line with the bending direction)
12

Improper

Proper

A radius should be applied to the edges of each bend

specimen per applicable specification
13

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Technical Services

Atmospheric Conditions Affect Weld Quality

Feedability

Many fabricators experience welding problems at different times of the year. Moisture (H2O) is a prime source of hydrogen.
At arc temperatures, water breaks down releasing hydrogen atoms that cause porosity in weldments. Shielding gas
supplies are controlled to very low moisture content (-70F dewpoint or lower). Likewise, the atmospheric conditions
in a fabricating facility need to be controlled to prevent moisture condensation from forming on electrode or base metal.

A - CONTACT TIP
B - JUMPER LINER
C - CONDUIT
D - LINER
E - OUTLET GUIDE

F - U GROOVE DRIVE ROLLS

G - INLET GUIDE
H - ALUMINUM ELECTRODE
I - ELECTRODE SPOOL
F

Relative Humidity vs. Dew Point

Relative Humidity %

t F Air-Metal

t C Air-Metal

87

3.6

1.1

75

7.2

2.2

66

10.8

3.3

57

14.4

4.4

50

18.0

5.5

44

21.6

6.6

38

25.2

7.7

34

28.8

8.8

30

32.4

9.9

26

36.0

11.0

Correct Contact Tip Size (I.D. and length)

Torch and Nozzles

23

39.6

11.9

I.D. 10% larger for hard wire

Straight nozzles aspirate less air than tapered

21

43.2

13.2

I.D. 20% larger for soft wire

Water-cooled torches are more efficient

18

46.8

14.3

Longer is better

Curved torches require more drive force

16

50.4

15.4

Remove burrs from tip entrance

A
B

Example: If the relative humidity in the weld area is 75%, the base metal and electrode must be no colder than 7.2F below the air temperature
to prevent moisture condensation.

H
E

Aluminum welding equipment demands attention to detail as feedability affects performance and productivity. Below are
areas of concern that can improve feedability, reduce downtime, and minimize maintenance costs.

Overheated torches can melt liners and ruin parts

Polish, clean, and inspect contact tips

Do not bend or crimp tips

Aluminum and argon lower the duty cycle of torches

(for torches rated with low voltage and CO2 gas)
Push/pull for whip lengths over 9 ft. (3 m)

Possible Solutions

Gun Liners and Wire Guides

1. Bring material into work space 24 hours prior to usage. This allows the temperatures to stabilize.

Teflon is soft and can hold embedded particles

2. Store filler material in an oven.

Nylon is tough, holds its shape and reduces

embedded particles

3. Store base material vertically allowing air flow to help the material temperature to stabilize.

Right size liner

Cut to the proper length
Plastic guides such as Nylon work to reduce shavings

Slave in the rear push/pull reduces liner wear

and feeding issues
Drive Rolls
U-groove type reduces shavings
Clean and polish rolls regularly2
Inspect for sharp edges, embedded particles,
and misalignment
If V-groove are used on one side, use a flat
on the other
V-grooves rollers with an angle > 60 degrees
Plastic rolls can wear unevenly causing wire distortion

(1) AlcoTec offers a contact tip polishing kit (part no. TIP-TUBE)
(2) AlcoTec offers a drive roll polishing kit (part no. DRV-ROLLPOLISH)

14

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Technical Services

Excessive Face Reinforcement

Dilution

Welders completing groove welds often end up with excessive face reinforcement on their welds. Whether they just want
to make sure the joint is filled in or they think it makes the weldment stronger, it typically causes more potential for harm
than good. Excessive face reinforcement on a groove weld will typically create a larger stress riser which may increase the
odds of the weldment cracking because of fatigue. Note the location of the crack in the weld image below.

A weld essentially becomes a new alloy made up of the base and filler alloys. Dilution is the amount of base alloy that mixes
with the filler alloy to create the new weld alloy. There are multiple factors that affect the amount of base dilution into the
weld puddle. Although the welding parameters can change the dilution ratio, the easiest way to actually control it is by
modifying the joint design (see images below).

Dilution Ratios of Joints

80% Filler Metal

20% Base Metal

60% Filler Metal

40% Base Metal

20% Filler Metal

80% Base Metal

Depending on the alloys involved, simply changing the joint design may be enough to change the tensile strength of an
as-welded groove assembly. The image below shows the theoretical difference in dilution ratios by modifying the joint
design from a square butt to a single V-groove. The amount of base metal that is diluting the filler alloy is reduced in the
single V, making the overall magnesium content of the new weld alloy significantly higher.

Reinforcement Angle
A

Angle A Degrees

Maximum Stress
(3 Million Cycles)
ksi (MPa)

100

7.5 (52)

130

9.5 (66)

160

13.5 (93)

Depending on the other variables involved, this may be all that is needed to go from just missing the minimum tensile
strength to achieving it regularly (and with room to spare). Another benefit of reducing the amount of base metal dilution
is that the probability of stress cracking is typically reduced.
Weld Composition: Dilution Effect

Base Plate
6061

Filler Metal
5356

By increasing the reinforcement angle of the weld metal as

shown in these images, the maximum amount of stress the
assembly could withstand almost doubled.

Reinforcement Angle
A

Additionally, removal of the reinforcement can restore fatigue

performance to near un-welded condition in non heat-treatable
alloys or re-heat-treated surfaces.

1.7% Mg

20% Filler Metal

80% Base Metal
3.2% Mg

60% Filler Metal

40% Base Metal
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Technical Services

Aluminum Alloys

Heat-Treatable and Non Heat-Treatable Alloys & the Heat Affected Zone (HAZ)

Aluminum can be alloyed with several other elements such as copper, magnesium, manganese, zinc, and silicon.
Each of these can be added alone or in combinations for various considerations such as strength, fluidity, corrosion
resistance, and ductility.

Aluminum alloys can be separated into one of two groups,

heat-treatable and non heat-treatable. All aluminum
alloys can be strengthened through cold working operations,
but only the heat-treatable alloys can be strengthened
through thermal processes. Because of this characteristic,
the heat from arc welding processes affects each
group differently.

Working with aluminum is much like working with wood. Most power tools using carbide blades are suitable for cutting and
prepping joints for welding. These will remove metal quickly and will not leave a residue behind like grinding pads and stone
cutting wheels. The chips left behind contain most of the heat from the cut, and therefore, coolants or other lubricants are
not needed.
Once the cut is made, the surface should be as clean as possible. Carbide router bits also work well for joint preparation
where rounded edges are preferred as they take heat better than sharp edges, which can result in oxides.

Do

Do Not

Use carbide bits and blades

Use lubricants (cut dry)

Use higher speeds for cutting and prepping

Use oxy-fuel to cut aluminum

Use band saws with 3 to 4 teeth/in.

Carbon arc gouge

Remove plasma and laser cuts (1/8 in.)

Use power wire brushes with excessive pressure (smears aluminum)

Clean surfaces before wire brushing

Direct air tool exhaust toward weld joint

Avoid Plasma/Laser Cut Micro Cracks in Welds

Most aluminum alloys are annealed to their softest

condition when they reach approximately 650F (350C).
Considering that aluminum melts somewhere in the area
of 1100-1200F (600-650C) it can be expected that
portions of the Heat Affected Zone (HAZ) will reach the
annealing temperature during an arc welding process.
This results in the weld assembly enduring a thermal cycle
that can greatly change the properties of the weldment.
The completed weld assembly can be broken up into three
distinct areas:
1. Weld Metal
2. Heat Affected Zone (HAZ) adjacent to the weld
3. Base material beyond the HAZ which has been
unaffected by the welding operation.
Heat Treatable
All of the 2XXX, 6XXX, 7XXX, and a few of the 4XXX series
alloys are heat-treatable. This means that these alloys can
be strengthened, not only through cold working, but also
through thermal processes.
In the case of the heat-treatable alloys, the heat affected
zone presents some interesting dynamics. Although the
HAZ will see the annealing temperature during the arc
welding process, it is often not fully annealed. As a result
of the rate at which the assembly cools, a partial heat
treatment typically occurs, which generally results in
tensile strengths slightly higher than the annealed
strength of the alloy.

Micro-cracks are potential crack starters in aluminum welds.

However, the strength of the HAZ can also be negatively

affected by the amount of time it spends at the elevated
temperatures encountered during arc welding. This is the
time at temperature relationship, which drives the resultant
strength of the weldment. The longer the weldment is at
elevated temperatures, the weaker the HAZ is typically
expected to be. This overheating phenomenon can
actually result in a groove weld tensile strength below
the minimum required.

Non Heat-Treatable
This group includes all of the 1XXX, 3XXX, 5XXX, and the
remainder of the 4XXX series alloys. These alloys can only
be strengthened through strain hardening. Thermal treatments
cannot be used to strengthen these aluminum alloys.
The heating of the HAZ, which takes place during the arc
welding operation, is sufficient to anneal the base material
within the HAZ area, and return it to the alloys softest condition.
Unlike the heat-treatable alloys, non heat-treatable alloys do
not generally require extended amounts of time at elevated
temperatures to become annealed.
Annealing eliminates the strain hardening as well as the
microstructure that is developed as a result of cold working.
For this reason, the minimum tensile strength requirements
for as-welded non heat-treatable alloys, regardless of the
original work hardened temper, is based on the annealed
strength of the base alloy.
Non-Weldable Alloys
There are also a few heat-treatable alloys, which are
considered to be non-weldable. It is not that they cannot
be welded, but that they should not be welded if there is
ANY LIABILITY involved with the finished product. Due to
the chemistries of these alloys, arc welding temperatures
produce a microstructure that will lead to grain boundary
cracking and there is nothing that can be done to prevent it.
The two most common alloys in this group are 2024 and
7075, but there are many others.
Summary
When designed and welded properly, the tensile strength
of a groove weld will be determined by the HAZ. While the
heat from the arc welding process will affect both groups
of alloys, the reduction in strength in the HAZ will be fairly
predictable in the non heat-treatable alloys. Since the
heat-treatable alloys respond uniquely to the heat, the
resulting HAZ strength can be less predictable. In order
to obtain consistent results, the use of qualified weld
procedures is highly recommended.

For heat treatable aluminum alloys, 1/8 in. (3 mm) of material shall be removed by machining from plasma arc and laser
cut edges that will be welded. - AWS D1.2

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Technical Services

Considerations When Repairing Aluminum Structures

Shielding Gas for Arc Welding Aluminum

Identification of the Base Alloy

Shielding Gas Functions

Probably the most important, and usually the first step

in the repair operation, is identifying the aluminum base
alloy being repaired. If the base alloy type is unknown, one
could contact the original manufacturer of the component
to establish the aluminum base material type. If the base
material type is not available through a reliable source, it
is impossible to select a suitable welding procedure.

Provides a plasma for commutation of current

Protects the weld pool from reaction with air environment
Provides cleaning action, which partially removes the aluminum oxide from the base material (DCEP)

Properties of Shielding Gases

There are many different types of aluminum alloys,

some have very good weldability and others have extremely
poor weldability. Unfortunately, if the base material type
is not known, or unavailable, chemical analysis is the only
one reliable way of establishing the exact type of aluminum
alloy. A small sample of the base material must be sent
to a reliable aluminum-testing laboratory, and a chemical
analysis must be performed. Generally, the chemistry can
then be evaluated and a determination as to the most
suitable filler alloy and the welding procedure can be made.

The amount of reduction in strength and the size of the

area affected is dependent on the original condition of the
base material prior to welding and the temperature and
time at temperature of the base material during welding.
The as-welded strength, as opposed to the original base
material strength, may need to be considered after welding.

Cleaning and Material Preparation Prior to Welding

Repairing High Performance Aluminum Alloys

It is very important to clean the repair area completely

prior to performing the weld repair. This is typically
achieved using a degreasing solvent to remove
hydrocarbons followed by stainless steel brushing to
remove the aluminum oxide. More aggressive filing, or
chemical cleaning, may be required for some applications.

Another consideration associated with the repair of a

small group of aluminum structures is the temptation to
repair high performance, typically high replacement priced
components, made from specialty aluminum alloys.

In situations where it is necessary to remove existing weld

or base material in order to conduct the repair, you need
to consider the methods available to perform this operation
as well as their effect on the finished weld. If you need to
remove a crack in the surface of a weld prior to re-welding,
you must use a method that will not contaminate the base
material to be welded. Care should be taken when using
grinding discs as some have been found to contaminate
the base material by depositing particles into the surface of
the aluminum. Routing and chipping with carbide tools is
often found to be a successful method of material removal.
Base Material Strength Reduction After Welding
There may be considerations relating to the effect of
the heating of the base material during the repair welding
process. Aluminum alloys are divided into two groups:

Cracked repair weld due to improperly preparing the repair area.

Argon

Helium
Advantages

Good arc initiation and stability

Higher arc voltage

More effective shielding

Broad weld root width

Lower cost

Reduced porosity

Good cleaning

Disadvantages
Poor cleaning
Narrow weld root width

Poor arc initiation and stability

Higher cost
Higher flow rates required

These materials are often found on aircraft, hand gliders,

sporting equipment, and other types of high performance,
safety-critical equipment, and are not usually welded on
the original component. There are a small number of
high-performance aluminum alloys that are generally
recognized as being un-weldable.
Summary
There are many considerations associated with the
successful repair of aluminum alloys. Most important is
to understand the many different aluminum alloys and that
they all require indvidual consideration. The majority of the
base materials used for general structural applications can
be readily repaired using the correct welding procedure.
The majority of welded aluminum structures are designed
to be used in the as-welded condition and, therefore, with
the correct consideration, repair work of previously welded
components can be conducted satisfactorily.

Argon

Helium

1. Heat-treatable
2. Non heat-treatable
Typically, the non heat-treatable alloys are used in a
strain-hardened condition and the heat-treatable alloys
are usually used in one heat-treated form or another.
During the welding process, the heat introduced to the
aluminum base will generally reduce the strength of the
base material in the heat-affected zone (HAZ).
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Technical Services

Easy Weld Quality Tests

Easy Weld Quality Tests

Lack of fusion and porosity can be considered the two most common discontinuities in aluminum welds. If youre
making changes to your process to reduce these items, youll want to be able to check your weld quality right away.
Below are a few methods you can use for quick weld quality checks.

An easy way to examine the cross-sectional profile of a weld is to perform a poor-mans etch. This can be done on fillet
and groove welds. It involves cutting the weldment to expose the cross section and polishing it as smoothly as possible.
Then warm up the sample (warm to the touch is sufficient) and spray the face to be etched with Easy Off oven cleaner.
The chemical in this cleaner (sodium hydroxide) will etch the surface after about 20-30 seconds. Rinse the sample, dry it
(compressed air cans work nicely), and then dust it with a clear lacquer.

Fillet Welds
You can easily check fillet welds for both lack of fusion and
porosity using the fillet fold over test. Weld one side only of
a tee joint and then fold the weldment over as shown here.
If the weld breaks, examine the internal structure of the
weld metal (examples are shown below).

Fold over test

Complete Fusion

Lack of Fusion

Groove Welds
Since groove welds cannot simply be folded over, a nick-break procedure can be done to examine the internal weld structure.

Porosity will show up as very shiny, spherical inclusions.

Use a saw to notch each side of a sample taken from a groove weld assembly, as shown.

Lack of fusion is evident when the sharp edge of the vertical component can still be seen under the weld metal.

Clamp one end in a vice and strike the other end with a hammer to break the sample.

Porosity

Lack of fusion/void

Sound weld metal

When complete fusion is achieved, the edge of the vertical component will be melted away by the weld metal.

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Technical Services

Weld Cracking

Weld Cracking

Common Causes and Cures

There are two types of cracks that can occur in aluminum welds: stress cracks and hot cracks.
Stress cracks occur when the weld is simply unable to withstand the forces applied to it. This can be due to a poor joint
design that is welded as designed, a weld that is just not strong enough for the application (not designed properly) or an
improper weld. Images 1A and 1B show fillet weld examples. Image 1A shows the profile of an acceptable weld. Image 1B
shows an excessively concave weld that failed through the effective throat (refer to Image 2). If the weld is inadequate for
any of the above mentioned reasons, it is very possible it will not withstand service conditions.

Different alloying elements affect the melting temperatures and ranges of aluminum. Alloys with a larger liquid to solid range
will have a greater tendency to hot crack. The graph shows where each chemistrys peak of crack sensitivity will be based
on the percentage of the major alloying element.
Image 1A

Image 1B

Crater cracks may occur as a result of stress and/or chemistry. Crater cracks that are caused by stress typically occur
when the weld termination point (crater) has a smaller cross section than the rest of the weld and simply cannot withstand
the forces applied during the solidification process (see Images 3A and 3B).
Because of their chemistry, some base materials are more susceptible to hot cracking than others. Welds made on these
alloys need to be flooded with enough of the filler alloy to change the chemistry and move it away from the crack sensitive
range. Since the crater is typically smaller in cross-section, there is often not enough filler alloy added to change the weld
pool chemistry and it becomes prone to hot cracking, even though the remainder of the weld is not.

Image 2

Hot cracks are a result of the chemistry. It can be the chemistry of the base alloy, the filler alloy or the combination
making the weld itself. The graph that follows shows the hot cracking sensitivity for some of the most common aluminum
alloy groups; Silicon (4XXX), Copper (2XXX), Magnesium (5XXX), and Magnesium-Silicide (6XXX).

Image 3A

Image 3B

Since weld cracks can be the result of stress, chemistry, or a combination, determining the root cause can be difficult.
For assistance in troubleshooting weld cracking concerns, please contact AlcoTec Technical Services at 1-800-228-0750.

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Technical Services

Performance Improvement - Increasing Wire Diameter

Filler Alloy for Welding 6061-T6

What affect does increasing wire diameter have on the welding process?
Some advantages of increasing wire diameter are: better fusion/penetration, increased travel speeds, higher deposition
rates, lower price per pound, and better feedability.

One of the most frequently asked aluminum welding questions is What filler alloy do I use for welding 6061?.
The AlcoTec filler alloy chart has several suggested options of filler alloys to use with 6061. From a chemistry stand point,
there are very few options that are not acceptable. However, there are a few elements to consider when choosing the most
appropriate filler alloy to use.

Due to the physical and mechanical properties of aluminum, it is very feasible to increase wire diameter and either:
1) go faster to increase production rates or, 2) make a larger weld without slowing down. The tables below show the results
from using larger wire for each goal. The table layout shows the percent increase between each wire increment as well as
the increase if you were to skip a level.

1. Ease of welding - this is the relative freedom from weld cracking. By use of hot cracking sensitivity curves
(see page 25) for the various aluminum alloys, and through the consideration of dilution between filler alloy and
base alloy, we can establish the filler alloy/base alloy crack sensitivity rating.

Common Bead Width

2. Strength of welded joint - consideration of the tensile strength of groove welds and shear strength of fillet welds,
when welded with different filler alloys, can prove to be extremely important during welding design. Different filler
alloys, which may exceed the as-welded tensile strength of the base material, can be significantly different in
shear strength performance.

Diameter (in.):

.047

.062

.071

.094

Amps

223

274

319

375

Volts

22.5

23

24

25

Wire Feed Speed (ipm)

523

366

295

180

Bead Width Target (in.)

0.45

0.45

0.45

0.45

Travel Speed (ipm)

26

35.8

42

49

5. Sustained temperature services - the reaction of some filler alloys at sustained elevated temperature (above 150F).
This may promote premature component failure due to stress corrosion cracking.

Percent Increase in Travel Speed

37.7

17.3

16.7

6. Color match - base alloy and filler alloy color match after anodizing can be of major concern in some cosmetic applications.

61.5

36.9

88.5

.047

.062

.071

.094

Amps

225

258

264

375

Volts

23

23

23

26

Wire Feed Speed (ipm)

531

366

271

180

Travel Speed (ipm)

27

27

27

27

0.422

0.480

0.582

0.688

13.7

21.3

18.1

37.9

43.2

62.9

Bead Width (in.)

Percent Increase in Travel Speed

4. Corrosion resistance - a consideration for some environmental conditions and are typically based on exposure
to fresh and salt water.

7. Post weld heat treatment - the ability of the filler alloy to respond to post weld heat treatment associated with filler
alloy chemistry and joint design.
These are all elements that must be considered when selecting a filler alloy for welding on 6061. It is the application of the
completed weldment that will drive which alloy should be used for welding.

Common Travel Speed

Diameter (in.):

3. Ductility - a consideration if forming operations are to be used during fabrication, and may also be a design
consideration of service if fatigue and/or shock loading are of importance.

This is just one step toward improving performance and productivity. Other tools and techniques can be found
throughout this guide.

Color Match After Clear Anodize

Base Metal: 6061

6061


6061
Welded with 5356

26

6061


6061
Welded with 4043

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Technical Services

Technical Services

The Affect of Texture on Anodizing

What if you have welded a base material with a filler alloy that has an A rating for color match, but can still see the weld?
When a part is anodized, the oxide layer that is added follows the contour of the part, it does not fill in the valleys to make
a level surface. It is not possible to see the actual surface texture without the aid of magnification, but when the light reflects
off of the base material, you will see the difference.
The image below shows how the light will pass through the anodized layer and then reflect back through it - this is
where the perceived color match comes from. Wrought products have very smooth surfaces where cast products do not.
When a rolled or extruded product (wrought) is welded, the weld is actually a cast structure. Since the textures are now
different, the light will reflect differently and the weld will still be visible even though it is the same color.
Therefore, to make the weld as close to invisible as possible, you can add a texture to the entire surface. This can be
done using a variety of methods (bead blasting, sand blasting, sanding, etc.).

Color Matching
Accomplished by selecting proper filler alloy and altering surface of the part.

Recommended
RecommendedWelding
WeldingParameters
Parameters
Square - Groove Weld
Nominal Plate Thickness
in.

Gap

Filler Wire Diameter

Wire Speed

Travel Speed

Wire Consumption

mm

in.

mm

in.

mm

Amps

Volts

ipm

m/min

ipm

cm/min

lbs/100 ft.

kg/m

(.078)

.030

0.8

80

18-21

460

11.7

40

102

0.67

.01

1/8

(.125)

0-1/32

0-0.5

.035

0.9

130

19-22

480

12.2

40

102

0.75

.01

5/32

(.156)

0-3/64

0-1

.040

1.0

160

20-23

450

11.4

40

102

1.25

.02

5/64

Single V-Groove

(typical included groove angle = 60)

Nominal Plate Thickness

in.

Gap

Filler Wire Diameter

Wire Speed

Travel Speed

Wire Consumption

mm

in.

mm

in.

mm

Amps

Volts

ipm

m/min

ipm

cm/min

lbs/100 ft.

kg/m

3/16

(.187)

.035

0.9

175

19-23

750

19.1

40

102

2.6

.04

1/4

(.250)

.047

1.2

195

20-24

430

10.9

40

102

4.6

.07

5/16

(.313)

.047

1.2

220

21-25

465

11.8

35

89

7.2

.11

3/8

(.375)

10

0-1/16

0-1

.062

1.6

240

22-26

320

8.1

35

89

10.3

.15

1/2

(.500)

12

0-1/16

0-1

.062

1.6

275

23-27

380

9.7

30

76

18.3

.27

3/4

(.750)

19

0-3/32

0-2

.071

1.8

290

24-28

335

8.5

24

61

41.3

.61

(1.00)

25

0-3/32

0-2

.094

2.4

330

26-32

180

4.6

18

46

73.4

1.09

Horizontal Fillet Weld

Nominal Plate Thickness
in.

mm

Gap
in.

Filler Wire Diameter

mm

Wire Speed

Travel Speed

Wire Consumption

in.

mm

Amps

Volts

ipm

m/min

ipm

cm/min

lbs/100 ft.

kg/m

5/64

(.078)

N/A

.030

0.8

100

18-20

500

12.7

41

104

0.4

.01

1/8

(.125)

N/A

.035

0.9

140

19-21

580

14.7

31

78

0.6

.01

5/32

(.156)

N/A

.040

1.0

150

20-22

425

10.8

20

51

1.6

.02

5/32

(.156)

N/A

.047

1.2

180

20-22

410

10.4

25

64

1.6

.02

3/16

(.187)

N/A

.047

1.2

190

21-23

425

10.8

22

56

2.2

.03

3/16

(.187)

N/A

.062

1.6

220

21-23

285

7.2

26

66

2.2

.03

1/4

(.250)

N/A

.047

1.2

210

22-24

480

12.2

20

51

4.0

.06

1/4

(.250)

N/A

.062

1.6

230

22-25

300

7.6

25

64

4.0

.06

5/16

(.313)

N/A

.062

1.6

230

23-26

300

7.6

20

51

6.2

.09

3/8

(.375)

10

N/A

.062

1.6

240

23-26

325

8.3

18

46

8.9

.13

1/2

(.500)

12

N/A

.071

1.8

280

24-28

335

8.5

24

61

15.9

.24

Outside Corner Joint

Nominal Plate Thickness
in.

Color matching is accomplished by hiding the differences.

mm

Gap
in.

Filler Wire Diameter

mm

Wire Speed

Travel Speed

Wire Consumption

in.

mm

Amps

Volts

ipm

m/min

ipm

cm/min

lbs/100 ft.

kg/m

5/64

(.078)

N/A

.030

0.8

80

18-20

460

11.7

40

101.6

0.4

.01

1/8

(.125)

N/A

.035

0.9

110

19-21

480

12.2

30

76.2

0.6

.01
.02

5/32

(.156)

N/A

.040

1.0

130

20-22

433

11.0

26

66.4

1.6

3/16

(.187)

N/A

.047

1.2

155

21-23

365

9.3

22

55.9

2.2

.03

1/4

(.250)

N/A

.047

1.2

185

22-24

420

10.7

20

50.8

4.0

.06

5/16

(.313)

N/A

.062

1.6

195

23-26

260

6.6

12

30.5

6.2

.09

3/8

(.375)

10

N/A

.062

1.6

230

23-26

300

7.6

20.3

8.9

.13

1/2

(.500)

12

N/A

.071

1.8

255

24-28

315

8.0

20.3

15.9

.24

NOTE: Welding parameters were developed utilizing the GMAW process with 100% argon shielding gas under laboratory conditions and are provided as guidelines only.
For 5XXX series electrodes use a welding amperage on the high side of the range and an arc voltage on the lower end of the range. For 1XXX, 2XXX and 4XXX series electrodes
use the lower amperage and higher arc voltage.

AlcoTec Wire Corporation / alcotec.com / 1.800.228.0750

29
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Filler Alloys

Characteristics

319.0 333.0 354.0

355.0 C355.0 380.0

413.0 443.0 444.0

356.0 A356.0 A357.0
359.0

7005 7021
7039 7046
710.0 711.0

6061
6070

6005 6060
6063 6101
6151 6351
6951

5454

511.0 512.0 513.0

514.0
5154 5254

5086 5056

5083 5456

5052

5005 5050

3004

3003

2219

2014 2036
1100
1060 1070
1080 1350

2319*
4043/4047*
4009*
4145*
5554
4043/4047*
4145*
4008*
5554
4043/4047*
4145*
5183
5356
5554
5556
5654
4043/4047*
4145*
4643*
5183
5356
5554
5556
5654
4043/4047*
4145*
4643*
5183
5356
5554
5556
5654
5183
5356
5554
5556
5654
5183
5356
5554
5556
5654
5183
5356
5554
5556
5654
5183
5356
5554
5556
5654
4043/4047*
5183
5356
5554
5556
5654
1100
4043/4047*
4145*
5183
5356
5556
1100
4043/4047*
4145*
5183
5356
5554
5556
1100
4043/4047*
4145*
2319*
4043/4047*
4145*
2319*
4043/4047*
4145*
1100
4043/4047*
1100
1188
4043/4047*

2014
2036

1100

W S

D C

T M W S

D C

A
B
A

C
B
A

B
A
B

A
A
A

A
A
A

A
B
A

C
B
A

B
A
B

A
A
A

T M W
B
A
C
A
B
A
A

B
A

B A
A B

A
B

A
A

B
A

B A
A B

A
B

A
A

B B
A A

A
B

C C

C C

B
A

A
B

B
B

A
B

B
A

A
A

A
A

B
B

A
B

B
A

A
A

A
A

E C
D D

A
B

A
A

E C
D D

A
B

B
B
B
B

A
B
C
A

B
B
B
B

A
B
C
A

A
A

E C
D D

A
A

E C
D D

B
B
B
B

A
B
C
A

B
A
A
B

A
A
A
A

B
B
B
B

A
B
C
A

B
A
A
B

A
A
B
A

A
B
C
A

B
A
A
B

A
A
A
A

A
A
B
A

A
B
C
A

B
A
A
B

B
A
A
B

A
A

A
B

A
A

B
B
A
B

A
A
A
A

B
A
A
B

A
B

B
B
A
B

5005
5050

3004

T M W
A
A
A
A
B
A
A

D C

T M W S

D C

T M W S

D C

T M W S

D C

C
B
A

B
A
B

A
B
B

A
A
A

A
B
A

C
B
A

B
A
B

A
B
B

A
A
A

A
A

A
A

B
A

B
A

A
B

A
A

A
A

B
A

B
A

A
B

A
B

A
A

A
A

A
A

B
A

B
A

A
B

A
A

A
A

C C

A
A

B
B

A
B

B
A

A
A

A
A

E C
D D

A
B

B A B
B B A
C C A
A B A B
C C A
A
C
A D D

A
A
A
A
A
A
B

B
B
B
B

A
B
C
A

B
A
A
B

A
A

E
D

C
D

A
A
A
A

B
B
B
B

A
B
C
A

B
A
A
B

A
A
A
A

A
A
B
A

A
B
C
A

B
A
A
B

B
A

B
A

B
A

A
B

A
A

A
A

B
A

B
A

A
B

A
A

A
A

A
A
A
A
B
A

B
A

A
B

A
A

A
A

B
A

B
A

A
B

A
A

A
A

A
A

A
A

A
B

A
B
C
A

B
A
A
B

A
A

C
D

A
A
A
A

B
B
B
B

A
B
C
A

B
A
A
B

A
A
A
A

A
A
B
A

A
B
C
A

B
A
A
B

A
A

B
B
A
B

A
A
A
A

B
B
B
B

C
B
A
A
A

B
A
B
A
A

A
B
B
A
A

A
A
A
A
A

A
B

C
B

B
A

A
B

A
A

A
B
A
A
A

A
A

A
A

A
A

A
A

A
A

A B A B
A B B A
A C C A
A B A B
B C C A
A D C

A
A
A
A
A
A

A A B
A B A
B C A
A A B
B C A
A D C

A
A
A
A
A
A

A
A

A
B

A
A

B
B
A
B

A
A
A
A

A
A
A
A
A
A
A
A

B A
B B
B C
B A
C C

B
A
A
B
A

B A B
B B A
B C A
B A B
C C A
A A B
A B A
B C A
A A B

A
A
A
A
A

B
B
B
B
A
B

A
A
A
A
A

A
A
A
A
A
A
A
A
A

A A B B
A B A B
B C A A
A A B B
B C A A
A A B A
A B A A

A A A B B
A A B A B
A B C A A
A A A B B
B B C A A
A A A B A
A A B A A

A
A
A
A
B
A
A

A A B B
A B A B
B C A A
A A B B
B C A A
A A B A
A B A A

A A A B B
A A B A B
A B C A A
A A A B B
B B C A A
A A A B A
A A B A A

A A A B B
A A B A B
A B C A A
A A A B B
B B C A A
A A A B A
A A B A A

A
A
A
A
B
A
A

A
A

A
B

B
A

A
A

A
A

A
A

A
B

B
A

A
A

A
A

A
A

A
B

B
A

A
A

A
A

A
A

A
B

B
A

A
A

A
A

A
A

A
B

B
A

A
A

A
A

A
B
B

C C
A B
B A

A
B
B

C C
A B
B A

C C
A B
B A

C C
A B
B A

A
A

A
B
B

C C
A B
B A

A
A

A
B
B

A
A

A
B
B

A
A

C
A
B
C
C
C
D
A
B
C
C

E
D
C
A
B
A
E
D
C
A
B

A A
D A
E B
C
B
C
A A
D A
E B
C
B

C
A
B
B C
B C
B C
A D
A
B
B C
B C

E
D
C
A
B
A
E
D
C
A
B

A A
D A
E B
C
B
C
A A
D A
E B
C
B

C
A
B
C
C
C
D
A
B
C
C

A A
D D A
C E B
A C C
B B C
A C C
A A
D D A
C E B
A C
B B

C C

B
A

A
D

B
B
B

A
B
A

B
A
B

B
B
B

A
B
A

A C
C A A A
B B A A
A C B A
2319*
4043/4047*
4145*

A
A
A

A
A
A

C A C
C C A
B B B
A A C

A
A
B

A
A
A

B
A

B
A

A
A
A

A
A

A
A

A
A

A
A

B
A

B
A

B B
A A
B B
A A
B B
C C
A A

A
B
A
B
A
A
B

A
A
A
A
A
A
A

A
A
A
A
A
A
A

B
A
B
A

B
A
B
A

A
B

B
B
B
A

B
B

A
A
B

A
B

B
A

A
A
A

C A C
C C A
B B B
A A C

B
A

A
A
A

A A A
B A A
A A A
B A A
1100
1188
4043/4047*

5083
5456

5052

S D C
A A A
D C D
C B C
B C B

A
A

3003

T M W
A
B
A
C
A
B
A
A

A
A

S D C
A A A
D C D
C B C
B C B

2219

B
A
B
A
B
B
A
C
B
A
A

B
A
A
C
B
A
C
B

A A A
B A A
A A A
B C A
C B A
A A A
B C A
C B A
1100
4043/4047*

B
A
A

B A A A
A B A A
A A A A
C B C A
B C B A
2319*
4043/4047*
4145*

B
A
A

B
A
A
A

A
A
A

B
B
B
A

B
B
B
A

A
A
A
A

B A C C
B B B C
C C A B A
B A C C
1100
4043/4047*
4145*

A
A
A
A

A
A
A
A

A
A

A
A

C
B
C
1100
4043/4047*
4145*
5183
5356
5554
5556

B
B
B

B A
B B
B C
B A
C C

B
A
A
B
A

B
B
B
B
C
A
A
C
A
B
A
A
C
A
B
A
A
C
A
B
A
A
C
A
B
A
A
A
C
A
B

A
B
C
A
C
A
B
C
A
C
A
B
C
A
C
A
B
C
A
C
A
B
C
A
C
D
A
B
C
A
C

M W S

D C

511.0 512.0
513.0 514.0
5154 5254

5086
5056
T M W S

D C

T M W S

A
A
A
A
A

A
A

A
B

B
A

A
A

A
A

A
A

A
B

B
A

A
A

A
A

D C

A A B
A B A
B C A
A A B
B C A

T M W S

A
A
A
A
A

6005 6060
6063 6101
6151 6351
6951

5454

A
A
A
A
A

A A
A B
B C
A A
B C

B
A
A
B
A

A
A
B
A
B

A
A
A
A
A

A A
A B
B C
A A
B C

B
A
A
B
A

A
A
B
A
B

A
A
A
A
A

A A
A B
B C
A A
B C

B
A
A
B
A

B
B
A
B
A

B
A
B
B
A

T M W S

D C

T M W S

D C

T M W S

D C

T M W S

D C

T M W S

A C
B B
A A
B A
B B
A A

B
A
B
A
A
B

A
B
B
A
A
B

A
A
A
A
A
A

A
B
A

B
A

B
A
B

A
B
B

A
A
A

A
B
A

C
B
A

B
A
B

A
A
A

A
A
A

C
A
B

B
A

B
A

A
B

A
B

A
A

A
A
A

B
A
A

A
B
A

A
B
A

A
A
A

B
B
A

A A B
A B A
B C A
A A B
B C A
A C C

A
A
A
A
A
A

A C C
B A B
B B A
C B A
B A B
C B A

A
B
B
B
B
B

A
B

C
B

B
A

A
B

A
A

A
B

C
B

B
A

A
B

A
A

B A
B B
A A

A
A
B

A
A
B

A
A
A

A A B
A B A
B C A
A A B
B C A

A A
A B
B C
A A
B C

A
A
A
A
A

A
A
A
A
A

A A B
A B A
B C A
A A B
B C A
A D C

A
A
A
A
A
A

B
A
A
B
A

B
B
A
B
A

A D C
B B A B
A B B A
B C C A
B B A B
A C C A

A
B
B
B
B
B

B
A
A
B
B
A B
B B
A B
A A A
B B
A B
B B
A B
A A
B B
A A
B A
A A
A A
B A
A A
B A
A A
A A
B A
A A
C B A
B C
A C
A A A
B C
A B
1100
4043/4047*
4145*
5183
5356
5556

A
A
A
A
A
A
A
A
A
A
B
A
B
B
A
A
A
A
A
B
A
A
A
A
B
B
A
B
B
A

A
A
B
A
B
A
A
C
A
B
A
A
B
A
B
A
A

A
B
C
A
C
A
B
C
A
C
A
B
C
A
C
A
B

B
A
A
B
A
B
A
A
B
A
B
A
A
B
A
B
A

A
A
B
A
B
B
B
A
B
B
A
A
A
A
A
A
A

A A A
A A B
A B C
A A A
A B C
A A A
A A B
A C C
A A A
A B C
A A A
A A B
A B C
A A A
B B C
A A A
A A B

B A
A A
A B
B A
A B
B B
A B
A A
B B
A B
B A
A A
A A
B A
A A
B A
A A

A B A
A B B
A C C
A B A
A C C
A A A
A A B
A B C
A A A
A B C
A A A
A A B
A B C
A A A
B B C
A
A

A (3) B
A
A

A
A

A
A

4043/4047*
5183
5356
5554
5556
5654

5183
5356
5554
5556
5654

B B
A B
A A
B B
A A
B B
A B
A A
B B
A B
B B
A B
A A
B B
A A
5183
5356
5554
5556
5654

A
A
A
A
B
A
A
A
A
A
B
A
B
A
A

B
B
C
B
C
A
A
B
A
B

A B B
B A B
C A A
A B B
C A B
A B B
B A B
C A A
A B B
C A B
5183
5356
5554
5556
5654

A
A
A
A
B
A
A
A
A
A

A
A
A
A
A

A
A

A D C A
B A B B
B B A B
C C A B
B A B B
C C A B
5183
5356
5554
5556
5654

A
A
A
A
B

A
A
A
A
B

A
A
A
A
A

A
A

B
A
B
B
B

A A B A
A B A A
B C A A A
A A B A
B C A A
4043/4047*
4145*
4643*
5183
5356
5554
5556
5654

4043/4047*
4145*
4643*
5183
5356
5554
5556
5654

How To Use This Chart

1.

Select base alloys to be joined (one from the side

blue column, the other from the top blue row).

2.

Find the block where the column and row intersect.

3.

This block contains horizontal rows of letters

(A, B, C or D) representative of the alloy directly across
from them in the filler alloy box at the end of each row.
The letters in each line give the A-to-D rating of the
characteristics listed at the top of each column W,
S, D, C, T and M (see Legend at right for explanation
of each letter).

4.

319.0 333.0
354.0 355.0
C355.0 380.0

D C

A
A
A
A
A

413.0 443.0
444.0 356.0
A356.0 A357.0
359.0

7005 7021
7039 7046
710.0 711.0

6061
6070

Analyze the weld characteristics afforded by each

filler alloy. You will find that you can trade off one
characteristic for another until you find the filler that
best meets your needs.

Example
If joining base alloys 6061 and 5086; first find the box
where the 6061 row and the 5086 column intersect.
Then notice that there are no ratings for filler alloys
4043/4047, 4145 or 4643 this means they are not
usually recommended for this base combination.
Filler alloy 5356 has an A rating for ductility, but a
B rating for strength. However, alloy 5556 has an
A rating for strength, but a B rating for ductility.
Therefore, it must be decided which attribute has
the highest priority.

A
A
A
A
A

B
A

B
A

D C

A
B

A
B

T M

A
A

A
B

2319*
4043/4047*
4009*
4145*
5554

4043/4047*
4145*
4008*
5554

4043/4047*
4145*
5183
5356
5554
5556
5654

Aluminum Filler Alloy Chart

SYMBOL

CHARACTERISTIC

Ease of welding
Relative freedom from weld cracking.

Strength of welded joint (as-welded condition)

Rating applies particularly to fillet welds.
All rods & electrodes rated should develop presently
specified minimum strengths for butt welds.

Ductility
Rating is based upon the free bend elongation
of the weld.

Corrosion resistance in continuous or alternate

immersion in fresh or salt water.

Recommended for service at

sustained temperatures above
150F (65.5C).

Color match after anodizing.

A, B, C, & D are relative ratings in decreasing

order of merit. The ratings have relative
meaning only within a given block.

*NOTES:
(1) Combinations having no rating are not usually recommended.
(2) The following filler alloys are heat-treatable and can
produce higher strength weldments after postweld solution
heat treatment and aging: 206, 357, 2319, 4008, 4009,
4145, and 4643.
(3) An A rating for alloy 5083 to 5083 and 5083 to 5456.
No rating for alloy 5456 to 5456.
(4) 4047 can be used in lieu of 4043. Alloy 4047 provides
increased fluidity for welding leak-tight joints, minimizes
solidification cracking, and has a slightly higher fillet weld
shear strength.

ALC-10016C 03/15

1060 1070
1080 1350

Aluminum Filler Alloy Chart

Base Alloys

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Training and certification

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33

Education

Education

Welder Certification and Qualification

AlcoTec School of Aluminum Welding Technology

CWIs (Certified Welding Inspectors) are often asked to certify welders. However, most of these requests should actually
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According to the AWS (American Welding Society):

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Final certification will provide transferable credentials that you may take with you wherever you go.
To become certified, one has to schedule a visit to an AWS ATF (Accredited Test Facility) and perform the testing there.
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An AWS certification is transferable, meaning any employer must recognize it.
Qualification
This simply refers to a welder testing to the requirements set forth in an applicable code. For most U.S. applications,
this would be an AWS code book. The steps to gain qualification are a little simpler than certification.
Basically, one must insure the welding, inspection, and mechanical testing are conducted in accordance with the
respective code. This does not necessarily require a CWI, but an independent CWI is generally contracted to assist.
One reason is to remove any conflict of interest within the organization conducting the testing. The other reason is to
insure the person qualifying the work has passed the testing requirements set forth by the AWS to properly interpret
the code.
A welder qualification is governed and maintained by the manufacturing facility and may or may not be recognized by
another employer.

In this three-day program, students learn metal preparation,

weld procedures, inspection procedures, processes for
joining aluminum and much more. AlcoTecs staff of
Metallurgical, Welding, and Quality Engineers and
Technicians bring their years of aluminum manufacturing
experience to this program, which educates participants
in the theory and general characteristics of various
aluminum alloys and tempers.
In addition, AlcoTec is pleased to offer the first program
for Aluminum Welding Technology designed specifically
for welding instructors. The Aluminum Welding Technology
Instructors Course provides welding instructors with the
information and tools they need to effectively introduce
their students to aluminum welding.

What You Will Learn

Metal preparation
Weld procedures
Workmanship
Inspection procedures
Understanding welding equipment
Processes for joining aluminum

Who Should Attend

Welding Engineers
Welding Supervisors
Welding Instructors
Product Design Engineers
Sales Managers and Representatives

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Education

AlcoTec School of Aluminum Welding Technology Course Outline

Classroom
Introduction to Aluminum Welding

Alloy and Temper Designation System

Historical perspective

Alloying elements

Industry information

Wrought alloys

The MIG (GMAW) Welding Process

Cast alloys

Transfer modes

Temper designations

Welding power sources

Welding Metallurgy

Shielding gases

Heat-treatable and non heat-treatable alloys

Wire feedability

Weld metal composition

The TIG (GTAW) Welding Process

Physical properties

Current types

Quality Control

Applications

Code and standard requirements

Procedures

Welder and welding qualification procedures

Metal Preparation for Welding

Acceptance criteria

Storage and handling

Testing methods

Cutting, beveling, and gouging

Defect measurement

Cleaning techniques

Design for Welding

Moisture control

Applications

Welding Procedures

Mechanical properties

Joint design

Design considerations

Machine settings

Distortion control

Weld profiles

Life cycle monetization

To learn more about what AlcoTec can do for you,

call 1.800.228.0750 or visit alcotec.com.

Laboratory
Equipment Evaluation

Welding Inspection and Testing

Drive roll geometry

Visual inspection

Liners and guides

Fillet weld fracture tests

Contact tips

Macros

MIG and TIG set up

Bend tests

Welding Test Samples

Beveling and pre-cleaning
Welding with MIG and TIG processes

Your aluminum partner.

Dye penetrant testing

AlcoTec Wire Corporation

2750 Aero Park Drive
Traverse City, MI 49686-9263

facebook.com/alcotecwire

X-Ray evaluation
Test Results and Code Requirements

Visit alcotec.com/weldschool for more information.

Fusion and penetration limits

Porosity limits
alcotec.com | 1.800.228.0750
A member of the ESAB Group, Inc.

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ALC-10029C 05/15

Undercut, overlap, and weld profile evaluation