Log In

Come Join Us!

Are you an
Engineering professional?
Join Eng-Tips Forums!
  • Talk With Other Members
  • Be Notified Of Responses
    To Your Posts
  • Keyword Search
  • One-Click Access To Your
    Favorite Forums
  • Automated Signatures
    On Your Posts
  • Best Of All, It's Free!
  • Students Click Here

*Eng-Tips's functionality depends on members receiving e-mail. By joining you are opting in to receive e-mail.

Posting Guidelines

Promoting, selling, recruiting, coursework and thesis posting is forbidden.

Students Click Here


Filler Material

Filler Material

Filler Material

Is it possible (recommended ?) to weld Aluminum Diecast (A360) & Aluminum Extrusion (6061 T6)? I tried to Google filler recommendation, couldn't find one for this combination.
When tried welding with filler 4043, even tough joint looks good, we noticed severe corrosion & crack overtime.

On the first had I want to see if these 2 alloys are OK to be welded.


RE: Filler Material

I am not a fan of welding A360. Try 5356.

RE: Filler Material

Weld failure between two different alloys (ANY alloys, and your aluminum is only an example) is very dependent on type of loads (compression, fatigue/cyclical), extreme sudden loads, or steady tension or torsion if a corrosive atmosphere or fluid is present. Dependent on weld shape and joint geometry, welder technique, and whether or not that particular welder at that particular time in that particular joint actually followed the weld procedure properly. Sometimes the weld itself is fine, but the joint design allows pockets where corrosive products build up and stress corrosion cracking occurs.

How did you qualify (test) the weld procedure and all of its parameters?

You appear to be making an assumption it is filler material, but you may not have examined all of the other causes thoroughly.

RE: Filler Material

May be its a combination of reasons for failure. Unfortunately I can't post the pictures because I don't own them all. I have asked for permission; hope to post them soon. Here is more information based on few comments here. Application is definitely a corrosive environment (by sea shore). obviously there is salty mist & humid wind.

I can see per this chart that 360/A360 aren't even on the weldable base materials. So I suspect that its a incorrect fusion altogether.



RE: Filler Material

Ah yes, Aluminum; almost a metal.

Best regards - Al

RE: Filler Material


I've always said 'plastic is not a real material, and aluminum is not a real metal'. Oh, and anything under ¾" thick is sheet metal.

"If you don't have time to do the job right the first time, when are you going to find time to repair it?"

RE: Filler Material


Best regards - Al

Red Flag This Post

Please let us know here why this post is inappropriate. Reasons such as off-topic, duplicates, flames, illegal, vulgar, or students posting their homework.

Red Flag Submitted

Thank you for helping keep Eng-Tips Forums free from inappropriate posts.
The Eng-Tips staff will check this out and take appropriate action.

Reply To This Thread

Posting in the Eng-Tips forums is a member-only feature.

Click Here to join Eng-Tips and talk with other members!


Close Box

Join Eng-Tips® Today!

Join your peers on the Internet's largest technical engineering professional community.
It's easy to join and it's free.

Here's Why Members Love Eng-Tips Forums:

Register now while it's still free!

Already a member? Close this window and log in.

Join Us             Close