How To Properly Use Filler Rod for Aluminum Welding

How To Properly Use Filler Rod for Aluminum Welding

Welding is commonly used to join aluminum parts. The process can seem challenging, but having the right filler rod makes all the difference. In this guide, we will cover the key things you need to know about aluminum filler rods and best practices for selection and welding so you can achieve excellent welded joints.

5xxx series: Al-Mg fillers help retain strength
6xxx series: Al-Si or Al-Si-Mg suitable for most
2xxx, 7xxx series: Special crack-resistant fillers

For a better selection, always consult your welding specifications and filler manufacturer recommendations.

Proper Storage and Handling

Weld quality is heavily influenced by rod surface conditions. To maintain their good condition, store rods in a cool, dry place away from chemical vapors. Avoid temperature extremes and humidity. Keep rods in original packaging until use. Only remove surface coating just before welding and reseal partially used packages between welds.

Welding Techniques

Follow qualified procedures for parameters like polarity, currents, and stick-out distance based on rod size and position. The optimal travel speed for heat input is typically 5-25 ipm. Proper torch angles and continuous smoothing motion. Flaws endanger weld integrity. Common causes include moisture contamination, surface oxides or hydrocarbons, too long or short arc length, moving too fast, and uneven heat distribution. To prevent this from happening, store rods properly and follow the cleaning steps. Maintain the right stick-out distance from 1/2″ to 1-1/4″. Use only optimal travel speed and employ proper torch angle and motion.

Visually check all welds for flaws and do non-destructive testing on critical welds. Bend, tensile, and other destructive tests also validate weld quality. With the right filler rods and following good welding practices, you can achieve precise aluminum welds for aerospace, automotive, or any application.


Finding your filler rod takes some work. You’ve got to consider the base metal properties, alloys, tempers, weld processes, and joint design. But don’t worry, just follow the tips we covered and you’ll be excellently matched up in no time. Keep those rods clean and dry and pay attention to your welding basics. Any filler rod can do an adequate job, but the right one does it amazingly. Feel free to reach out at YK-Longshun to find your rod’s perfect match.

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