Aluminum Wire for Thick Section Welding

Specification

Applications and Solutions

• Structural Beams and Girders: Joining large, thick extruded or rolled plates for bridges, cranes, and large industrial supports.

• Pressure Vessels and Storage Tanks: Fabrication of longitudinal and circumferential seams in thick-walled vessels requiring high mechanical strength.

• Die and Mold Repair: Large diameter TIG rods used for high-deposition repair of massive aluminum casting flaws or worn tooling sections.

• Naval and Offshore Fabrication: Multi-pass welding of thick 5083/5456 hull plates where strength and fatigue resistance are mandatory.

FAQ

• Q: Why are larger diameter wires better for thick sections?A: Larger wires allow for a significantly higher current (>300A) and therefore a higher deposition rate. This is necessary to fill the large joint volume efficiently, as using small wire would require too many time-consuming passes.

• Q: How do you prevent cracking in multi-pass welds on thick aluminum?A: Crack mitigation relies on two main factors: 1) Using a highly crack-resistant filler metal like ER5183; and 2) Strict control of interpass temperature and sequencing to manage the high accumulated residual stress in the thick joint.

• Q: Can ER4043 be used on thick sections?A: ER4043 can be used on 6XXX thick sections, but the lower strength and higher susceptibility to HAZ softening under repeated thermal cycling make ER5356 or ER5183 the preferred choice for thick-section structural applications.