5XXX and 6XXX series aluminum alloys are the best for welding overall.
A: A common aluminum alloy, 6061-T6 is welded every day, so we assume it must be easy to weld. Unfortunately, it isn't. In fact, 6061 and the other 6XXX series alloys are relatively sensitive, and it isn't uncommon for people to have cracking problems with them.
First, some aluminum alloys cannot be welded without filler materials. Alloys such as 6061 will undergo solidification cracking if welded without filler metal. Furthermore, the correct filler material must be selected. For instance, welding a 6061 alloy with a 6061 filler metal will result in weld failure.
2000 Alloys:
This is a family of high-strength aerospace alloys. They are extremely sensitive to hot cracking and are the least weldable aluminum alloys. Specifically, 2024 is the least weldable. But there are a couple exceptions, 2219 and 2519, which can be readily welded with 2319 or 4043 filler metal.
Aluminium alloy 3003. In most cases, this is probably the best alloy for bending.
Can You Bend 5052 Aluminum? Aluminum alloy 5052 is a good candidate for bending. While the elongation isn't as high as the 3003 aluminum alloy, you still see a big difference between yield and tensile strength.
AA 5052 H32 is cold-rolled aluminium alloy having very high corrosion resistance with an industrial and marine environment, good formability, and good weldability out of other aluminium alloys and thus has been used for automotive and marine structural applications.
Generally speaking, aluminum's capacity to be welded (weldability) varies between different alloy series. It can range from “very good” to “unweldable by common arc welding methods.” That said, most aluminum alloys can be welded under the right conditions and by taking proper precautions.
A high-strength alloy, 5XXX aluminums are easily welded. Components made with this material, such as auto parts and plates, are strong and durable. 6XXX is a close runner up. While the most common aluminum alloy used in welding, it can crack when exposed to extreme heat for too long.
Material thickness: Most reputable MIG machines can be used to weld aluminium down to 3mm thickness. To successfully weld materials thinner than 3mm, it may be neccessary to use specialist MIG or TIG welders with pulse capability. (Note: to TIG weld aluminium, you will need an "AC/DC" machine such as the 202T).
Aluminum 5052 has a smoother finish than 6061, although it is not heat-treatable. Aluminum 5052 has a higher fatigue strength and modulus of elasticity than Aluminum 6061, making it an excellent forming alloy. Additional aluminum alloy 5052 characteristics include: Non-heat treatable.
What Makes Welding 2024 and 7075 Challenging? Aluminum alloys of 2024 and 7075 can become susceptible to stress corrosion cracking after welding. This phenomenon is particularly dangerous because it is not detectable immediately after welding. The cracking usually develops later when the component is in service.
6061-T6 is an all-around popular grade of aluminum that is also commonly used in marine applications. It has very good corrosion resistance and is precipitation hardened. These grades, for the most part, have additional chromium and manganese to help protect them from corrosive marine conditions.
As you may remember, we have discussed the fact that 6061 and all the other 6XXX alloys are very crack-sensitive.
Filler Alloy ER4043
While the 4043 filler alloy, a 5% Silicon alloy, is often used to weld 6061 base materials, it is not commonly used when the shear strength of the component is a predominant consideration.
Article Revised July 28th, 2022. It's often said that aluminum is a more difficult metal to weld than steel. While it's true that most welders start out by learning to weld steel before moving on to aluminum, it's not entirely accurate to say that one is more difficult than the other.
Types of metals: MIG welding works with most types of metals. You can use aluminum, stainless steel and mild steel. TIG welding is also compatible with these metals but works better with thinner gauge materials. Speed: TIG is a slower method but provides a higher level of detail.
Generally, two processes are used for aluminum welding: GTAW (TIG) and GMAW (MIG). Most welders in the business will say TIG is the better option for welding aluminum because it allows for better results on lighter gauge materials. When done correctly, TIG welding aluminum can produce quality welds.
The right Welder is essential if you're going to work with aluminum. For aluminum, a TIG – tungsten inert gas – welding machine is a better choice than a MIG machine. While MIG machines can be used, TIG machines are preferred by most professionals taking on complex aluminum welding tasks.
The first digit will tell you the primary alloying metals for each aluminum alloy, and it is the most important. You can use it to differentiate between different alloy “series” or “grades.” For example, all aluminum alloys that start with a 2 are known as 2xx. x series or grade 2xx.
It's possible to weld aluminum using stick welding methods, but it can be messy. Some of the best methods to use during the process include alternating or direct current TIG welding or MIG welding.
5052 is generally less expensive than 6061. In summary, certain aluminum alloys (especially 5052-H32) are excellent materials for NEMA rated electrical enclosures – especially if your enclosure is going to be used outdoors and/or heat dissipation is a consideration.
The most commonly used MIG aluminum welding wires are ER4043 and ER5356. ER4043 is a general-purpose MIG welding wire used to weld 2014, 3003, 3004, 4043, 5052, 6061, 6062, and 6063 aluminum alloys. The welds provide high ductility and excellent resistance to cracking.
6061 aluminum is much harder to permanently deform than 5052 (276 MPa VS. 193 MPa), showing both its increased strength and its formability issues. 5052 aluminum has a lower yield strength, but this serves it well as it takes less work to reach the plastic (or permanent) regions of deformation.