53563641C - Nexalloy ER5356 Aluminum MIG Wire 0.045 1lb Spool

Technical Overview of Nexalloy ER5356 Aluminum MIG Wire

The Nexalloy ER5356 is a premium general-purpose aluminum filler alloy designed for welding 5XXX series alloys. This 1lb spool, featuring a 0.045-inch (1.2mm) diameter wire, is engineered with a specific chemical composition that includes 5% Magnesium, along with controlled additions of Manganese, Titanium, and Chromium. This precise metallurgy significantly enhances the mechanical properties of the weld deposit, offering a typical tensile strength range of 38,000 to 40,000 PSI. The addition of Titanium refines the grain structure, while the Chromium and Manganese content boosts corrosion resistance, making this alloy the definitive choice for marine environments where saltwater exposure is a critical concern.

Unlike 4043 silicon-based alloys, the 5356 magnesium series does not rely on dilution from the base metal to achieve its strength, providing higher shear strength and ductility in the as-welded condition. It is compatible with base metals such as 5050, 5052, 5083, 5086, 5154, 5356, 5454, and 5456. The wire's melting range is approximately 1060°F to 1175°F, and it requires a welding current of Direct Current Electrode Positive (DCEP). Shielding gas requirements are typically 100% Argon or Argon/Helium mixtures for thicker sections to increase heat input.

One of the standout technical benefits of Nexalloy 5356 is its post-weld finishing capability. It provides an excellent color match when anodized, avoiding the dark gray or black discoloration often associated with 4043 alloys. This makes it suitable for architectural applications where aesthetics are paramount. However, it is not recommended for applications where the service temperature exceeds 150°F (65°C) due to susceptibility to stress corrosion cracking in high-magnesium alloys.

The 0.045-inch diameter offers a balance between deposition rate and heat control, suitable for medium to heavy gauge materials. The 1lb spool packaging is specifically designed for use with spool guns or push-pull systems that accommodate 4-inch spools, ensuring portability and ease of use in field applications.