- Thread starter robdxr2
- Start date
Richard.
Member
- Messages
- 18,344
- Location
- Cambridgeshire
Depends! Is it to practice on? If so the rod flavour doesn't matter. If your going to build something then there is a big difference between those two wires regarding strength, ductility, sensitive to cracking etc.
A lot of Alu grades will weld and tolerate both wire types but if I was to be on the safe side welding an unknown grade I'd go with the 5% si. (4043).
A lot of Alu grades will weld and tolerate both wire types but if I was to be on the safe side welding an unknown grade I'd go with the 5% si. (4043).
M
Member 66061
Guest
Richard.
Member
- Messages
- 18,344
- Location
- Cambridgeshire
I personally wouldn't do that. Even for practice it's not a good idea. Filler materials have other elements (mag and Si) that are added to the weld pool to aid with the joint in many ways. Strength , ductility, weld ability, etc. Cutting a Chunk off an unknown Alu to weld that Unknown Alu is more likely to be worse than using one that's probably a safe bet like the 4043. You can use or get pure aluminium filler rod but it's not a joining filler, more a cladding rod against corrosion etc. Extremely shiny surface finish like a mirror but in a joint designed to take any load would be pretty much useless.
Pure ally (1xxx series)* filler wire is for joining stuff, better choice than any of the 4xxx or 5xxx series for welding 1xxx and 3xxx series flavours of aluminium to themselves or each other. Especially when ductility, corrosion resistance and/or colour match (whether polishing or anodising) is important
None of the following really matters much when playing around/learning but FWIW...
shows how some alloying elements affect sensitivity to solidification (hot) cracking. Something like 1050 is 99.5% pure aluminium, weld it with a 4043 or 5356 (5% Si and Mg respectively) and the result is likely to be closer to the crack sensitive region than if 1050 was used. While hot cracking is (technique aside like leaving craters etc) very unlikely the extra strength of alloyed filler wires doesn't add anything useful to the part but they are harder & less ductile than the parent material...
One of the 6xxx series alloys on the other hand contains a little of both Si & Mg (the formation of magnesium silicide is what makes the 6xxx series harder/stronger and heat treatable) at around the % that puts it right in the middle of the crack sensitive region. Shear strips of it to use as filler and the result is likely to be a weld that cracks as it solidifies. Same deal with a 1xxx series filler wire as the Mg2Si needs diluting with either some extra Mg or Si
* All of the 1xxx series are at least 99% aluminium with the last two digits denoting purity i.e. 1100 is 99% pure, 1050 is 99.5% etc. The second digit denotes modifications to the origional alloy so something like 1450 aluminium is 99.5% pure but extra control is added to the remaining impurities, in this case the 4 means that it will contain specific traces of Ti which act as grain refiners
None of the following really matters much when playing around/learning but FWIW...
shows how some alloying elements affect sensitivity to solidification (hot) cracking. Something like 1050 is 99.5% pure aluminium, weld it with a 4043 or 5356 (5% Si and Mg respectively) and the result is likely to be closer to the crack sensitive region than if 1050 was used. While hot cracking is (technique aside like leaving craters etc) very unlikely the extra strength of alloyed filler wires doesn't add anything useful to the part but they are harder & less ductile than the parent material...
One of the 6xxx series alloys on the other hand contains a little of both Si & Mg (the formation of magnesium silicide is what makes the 6xxx series harder/stronger and heat treatable) at around the % that puts it right in the middle of the crack sensitive region. Shear strips of it to use as filler and the result is likely to be a weld that cracks as it solidifies. Same deal with a 1xxx series filler wire as the Mg2Si needs diluting with either some extra Mg or Si
* All of the 1xxx series are at least 99% aluminium with the last two digits denoting purity i.e. 1100 is 99% pure, 1050 is 99.5% etc. The second digit denotes modifications to the origional alloy so something like 1450 aluminium is 99.5% pure but extra control is added to the remaining impurities, in this case the 4 means that it will contain specific traces of Ti which act as grain refiners
That'll almost certainly be due to them being Irwin, min cutting width with decent aviation snips should be at least = to sheet thickness and can be around half the sheet thickness.
C
Chris Stevens
Guest
Mate of mine has made 1000s of aluminum motorcycle fuel tanks over the years, all welded with 1050 filler rod.
C
Chris Stevens
Guest
On some jobs 1050 is pretty much the only choice if part is to be polished and perfect colour match is required. Doesnt seem to weld as nice as alloyed fillers though.
