AWS A5.10/A5.10M · Aluminum
ER5356 Welding Electrode
ER5356 is the 5% magnesium aluminum filler — stronger than ER4043, stiffer to feed, and the choice when the joint must carry load or be anodized.
- 38 ksi tensile
- Polarity AC (GTAW), DCEP (GMAW)
- 4 positions
- Medium penetration
- TIG (GTAW) / MIG (GMAW)
What ER5356 means
| Part | Meaning |
|---|---|
| ER | Electrode or rod — usable for MIG or TIG |
| 5356 | Aluminum Association alloy 5356, nominally 5% magnesium with small chromium and manganese additions |
ER5356 specifications
| AWS specification | AWS A5.10/A5.10M |
|---|---|
| Process | TIG (GTAW) / MIG (GMAW) |
| Form | Solid wire / rod |
| Polarity | AC (GTAW), DCEP (GMAW) |
| Welding positions | Flat, Horizontal, Vertical, Overhead |
| Tensile strength (min) | 38 ksi (262 MPa) |
| Yield strength (min) | 17 ksi (117 MPa) |
| Elongation (min) | 17% |
| Impact toughness | Not applicable |
| Coating / core | None — bare wire or rod |
| Penetration | Medium |
| Deposition rate | High on MIG, moderate on TIG |
| Slag | None; mechanical oxide removal required before welding |
| Arc character | Slightly stiffer and less fluid than ER4043 |
| Shielding gas | 100% argon |
ER5356 amperage by diameter
Typical operating ranges. Start near the middle of the range, then adjust by sound and bead profile. Reduce 10–15% for vertical and overhead work.
| Diameter | Amperage range | Typical start |
|---|---|---|
| 0.030 in (0.8 mm) MIG | 60–175 A | 118 A |
| 0.035 in (0.9 mm) MIG | 70–200 A | 135 A |
| 3/64 in (1.2 mm) MIG | 100–260 A | 180 A |
| 1/16 in (1.6 mm) TIG | 40–90 A | 65 A |
| 3/32 in (2.4 mm) TIG | 80–130 A | 105 A |
| 1/8 in (3.2 mm) TIG | 120–190 A | 155 A |
Polarity: AC for TIG to provide oxide cleaning; DCEP for MIG. ER5356 is stiffer than ER4043 and feeds noticeably better through a long gun.
Shielding gas for ER5356
| Gas | Notes |
|---|---|
| 100% argon | Standard for TIG and MIG up to about 1/2 in. |
| 75% Ar / 25% He | Extra heat for thick plate and better wetting. |
| 50% Ar / 50% He | Heavy sections where argon alone runs out of penetration. |
Flow rate: 20–30 CFH (9–14 L/min)
What ER5356 is used for
- Boat hulls, marine structures and 5083/5086 plate
- Structural aluminum joints where shear strength governs the design
- Trailers, truck bodies and tanks
- Parts that will be anodized and need a color match
- Aluminum bicycle and motorcycle frames
Base metals
- 5052, 5083, 5086 and the 5xxx series
- 6061 where joint strength governs
- Marine aluminum structures
- Aluminum that will be anodized
Characteristics
- Roughly 40% higher tensile strength than ER4043 and much better shear strength in fillet welds
- Anodizes to a near match with common base alloys, where 4043 goes dark gray
- Stiffer wire feeds better through long MIG guns and push-pull systems
- More sensitive to hot cracking on high-silicon base metals and castings than ER4043
- Not recommended for sustained service above about 150 °F (65 °C), where magnesium above 3% can sensitize and lead to stress corrosion cracking
Storage and handling
Sealed and dry. Magnesium-bearing aluminum oxidizes readily and moisture becomes weld porosity.
- TIG rod in a sealed tube, MIG spools bagged with desiccant.
- Handle with clean gloves — skin oils are a hydrogen source.
- Wipe with acetone before welding and brush the joint with a dedicated stainless brush.
- Discard filler showing a white powdery oxide bloom.
Welding tips
- Use it on 5xxx base metals and wherever a fillet weld's shear strength governs the design.
- For anodized work, ER5356 is the only sensible choice of these two fillers.
- Preheat over 1/4 in to 250–300 °F (120–150 °C); avoid prolonged heat on 5083/5086 in marine service.
- Avoid it on high-silicon castings such as 356 — magnesium plus silicon in those proportions cracks; use ER4043 there.
- Feed problems usually mean liner and drive-roll setup, not the wire: use U-groove rolls and a nylon or graphite liner.
ER5356 frequently asked questions
Is ER5356 stronger than ER4043?
Yes. ER5356 runs about 38 ksi tensile against roughly 27 ksi for ER4043, and its shear strength in fillet welds is substantially higher. That is why structural and marine work specifies 5356.
Which filler anodizes better, 4043 or 5356?
ER5356. A 4043 weld anodizes dark gray to black and stands out sharply; 5356 comes much closer to the base metal color.
Can ER5356 weld 6061?
Yes, and it is preferred when the joint's strength governs. ER4043 is the more crack-tolerant choice on restrained 6061 joints and castings, so the selection depends on whether strength or crack resistance matters more.
Why is ER5356 not used above 150 F?
Aluminum alloys with more than about 3% magnesium can sensitize during long exposure to elevated temperature, precipitating a magnesium phase at grain boundaries that makes the metal vulnerable to stress corrosion cracking.
Why does ER5356 feed better than ER4043?
It is a harder, stiffer alloy. Soft 4043 wire buckles and birdnests in the drive rolls on a long gun, while 5356 pushes through more reliably.