Aluminum Filler Rod for TIG Welding

In aluminum alloy welding applications, TIG filler rods (Tungsten Inert Gas welding filler rods) are essential materials for achieving high-quality welds. Chalco specializes in the development and production of aluminum and aluminum alloy welding consumables, offering a stable supply of TIG-grade solid rods in various alloy grades, diameters, and customized packaging. Our products are widely used in high-precision welding scenarios across the aerospace, automotive, and industrial structural sectors.

What we offer is commonly referred to in the industry as aluminum filler rods or TIG rods, specifically designed for manual TIG (GTAW) welding processes. These rods provide excellent weldability, crack resistance, and corrosion resistance, and are especially compatible with 1xxx, 4xxx, 5xxx, and 6xxx series aluminum base materials.

Chalco aluminum filler rod product introduction

Product categories: Aluminum TIG Filler Rods; Meets AWS A5.10 / ISO 18273 and other international standards.

Suitable welding positions: Flat, Horizontal, Overhead, Vertical-Down, Vertical-Up (Filler rods can be used in all-position TIG welding with appropriate technique and joint preparation.)

Surface Finish: Bright, Cleaned, or Lightly Oxidized (Grey/Silver/White); Available in standard mill finish or brushed finish depending on alloy and storage condition

Common TIG filler rod alloys: Click to view [Alloy Details]

• 4043 / 4943 – For 6xxx series (e.g. 6061), excellent flow & crack resistance
• 5356 / 5556 – For 5xxx series (e.g. 5083), higher strength and corrosion resistance
• 4047 / 4643 – High silicon, for cast aluminum & shrinkage crack control
• 1050 / 1100 / 1070 – Pure aluminum, ideal for low-strength & corrosion-resistant joints

Popular diameters: Click to view [Product size and performance reference table]

• 0.035" (0.9 mm), 0.045" (1.1 mm), 3/64" (1.2 mm), 1/16" (1.6 mm)
• 3/32" (2.4 mm), 1/8" (3.2 mm), 5/32" (4.0 mm), 3/16" (4.8 mm)
• Custom diameters available upon request

Packaging specifications:

• TIG cut lengths: 10 pcs/bundle, 1 lb / 5 lb / 10 lb per tube
• Industrial box: 2.5 kg, 5 kg, or custom weight per carton
• Moisture-proof and export packaging available upon request

Hot-selling aluminum filler rods for TIG welding—— most popular alloy grades

Chalco offers a full range of TIG filler rods designed for optimal performance across a variety of aluminum welding applications. Below are our most in-demand alloy grades, each carefully selected to meet the strength, fluidity, crack resistance, or anodizing compatibility required in your projects.

Whether you're working with structural 6xxx aluminum, marine-grade 5xxx alloys, or pure aluminum for corrosion-resistant components, our hot-selling TIG rods cover the key welding needs of industries worldwide. Choose the right alloy based on your material, application scenario, or post-weld treatment requirements:

ER4043/ R4043 aluminum filler rod

ER4043 is a general-purpose aluminum TIG wire with silicon additives, offering good fluidity, crack resistance, and bright welds. It suits 6000 series alloys, supports heat treatment, and has higher tensile strength than ER5356.

Applicable welding positions: flat welding; horizontal welding; overhead welding; vertical welding downward; vertical welding upward

Tensile Strength (minimum requirement): 29 ksi

ER 5356 aluminum filler rod

ER5356 electrodes are popular aluminum TIG electrodes for general welding, ideal for 5000 series alloys and not heat treatable.

Applicable welding positions: flat welding; horizontal welding; overhead welding; vertical welding downward; vertical welding upward

Tensile Strength (minimum requirement): 38 ksi

Reference table: sizes and properties of Chalco aluminum filler rods

The following table lists the performance and parameters of the two most commonly used aluminum welding wires, ER4043 and ER5356, including typical welding current, voltage, welding speed, gas flow and other detailed information. If you need to know the performance parameters of other welding wires or have special requirements, please feel free to contact us!

4043 Aluminum filler material is a 5% silicon aluminum filler recommended for welding of 3003, 3004, 5052, 6061, 6063, and cast alloy such as 443, 355, 356 and 214.

5356 aluminum filler material is a 5% magnesium aluminum filler recommended for welding of 5050, 5052, 5083, 5356, 5454 and 5456.

Filler rod selection guide by welding process and base material

To ensure optimal welding performance and long-term structural reliability, selecting the correct filler rod for your base aluminum alloy and welding application is critical. The chart below provides recommended alloy pairings based on the most common aluminum grades and typical welding scenarios.Quick Quote

• For anodizing applications, avoid 4043 as it produces a gray/black weld; use 5356 instead
• For structural welds requiring higher strength, 4943 is often a better choice than 4043
• For crack-prone castings, prioritize 4047 due to its superior silicon content and fluidity
• Always match filler rod chemistry as closely as possible with the base alloy family for best performance

Product advantages of Chalco aluminum TIG filler rods

Chalco TIG filler rods are engineered to deliver reliable performance across diverse welding tasks, from lightweight structures to corrosion-resistant assemblies. Our products are trusted by manufacturers in aerospace, automotive, marine, and industrial sectors for their outstanding mechanical and welding characteristics.Quick Quote

• High Weld Quality: Smooth arc, clean welds, low spatter, ideal for critical joints
• Excellent Corrosion Resistance: Suitable for marine, chemical, and outdoor environments
• Crack Resistance & Flowability:High-silicon alloys like 4043 / 4047 reduce thermal cracking
• Lightweight with Good Strength: Ideal for aerospace, automotive, and structural applications
• Anodizing Compatibility: Alloys like 5356 offer better post-weld color matching
• All-Position Welding: Usable in flat, vertical, horizontal, and overhead positions

Chalco aluminum TIG filler rod application areas

Chalco filler rods are trusted by manufacturers worldwide for demanding aluminum welding projects across mobility, infrastructure, and precision industries. Welcome to contact. Quick Quote

Why choose Chalco as your aluminum TIG filler rod supplier

Full-process production capability: Chalco operates modernized production lines with in-house aluminum ingot melting, alloying, continuous casting, and precision rod drawing. Our integrated process ensures tight composition control and stable mechanical properties.

Advanced equipment for high precision: Equipped with high-speed wire drawing machines and automatic straightening & cutting systems, we ensure diameter tolerance within ±0.02 mm, optimized for smooth TIG feeding and consistent arc behavior.

Large-scale output with fast delivery: Monthly capacity exceeds 500 tons of aluminum filler rod, supporting both standard stock and custom alloy orders with short lead times and stable export supply.

Surface treatment & quality inspection: Products are processed through degreasing, anti-oxidation treatments, and online flaw detection to ensure surface cleanliness and welding stability.

Flexible packaging & export service: Standard 36” cut lengths; options for tube, box, or custom packaging Moisture-proof export cartons, pallet wrapping, and OEM labeling supported

Traceable materials & certifications: Alloy batches traceable from ingot to finished rod; documentation available: COA, MSDS, RoHS, REACH, CE

Global experience, one-Stop solution: Proven supply records across aerospace, automotive, shipbuilding, and industrial manufacturing; Chalco not only provides high-quality aluminum TIG filler rods, but also offers a complete portfolio of welding materials — including MIG wires, stick rod core wire, aluminum brazing rods, and TIG filler rods for stainless steel, copper, titanium, nickel, and other alloys — to support your full welding system.

Aluminum brazing rod

Low temperature welding rod

Zirconiated tungsten for aluminum

Aluminum gas welding rod

Oxyacetylene welding filler rod

Flux-Cored Wire

Stainless Steel TIG Welding Rods

Mild Steel TIG Welding Rods

Bronze TIG Welding Rods

Nickel Alloy TIG Welding Rods

Copper TIG Welding Rods

Alloy Steel TIG Welding Rods

Titanium TIG Welding Rods

Cast Iron TIG Welding Rods

Magnesium TIG welding rods

Aluminum stick rod core wire

Aluminum welding wire

Knowledge center and FAQ for aluminum filler rod or TIG filler rod

Chalco aluminum filler rod welding position

Can Chalco filler rods be used on cast aluminum?

Yes, silicon-rich alloys such as ER4047 or ER4043 are ideal for welding aluminum castings due to their high fluidity and reduced hot-crack sensitivity.

Which alloy is best for anodized aluminum parts?

ER5356 is recommended for welds requiring a color match after anodizing. ER4043 may result in a dark gray weld zone.

How to properly store and handle aluminum filler metal?

Store rods in a dry, temperature-stable environment. Avoid rapid temperature shifts to prevent condensation. Use sealed packaging or original cartons for optimal protection.

What shielding gas should I use with aluminum TIG filler rods?

Pure Argon (99.99%) is standard. For thicker materials or improved penetration, Argon + Helium blends may be used.

Are Chalco TIG rods compatible with both AC and DCEP current?

Yes. Most aluminum TIG filler rods work well with AC current. Some rods also support DCEP (Direct Current Electrode Positive) in specific applications — please consult datasheets.

What equipment should I use to ensure smooth aluminum wire feeding?

Use a spool gun or push-pull system for MIG, U-groove rollers, nylon liners, and contact tips with slightly oversized apertures to reduce friction and ensure steady feed.

Can I order customized lengths or packaging for filler rods?

Yes. Chalco offers standard 36" TIG rods and supports custom diameters, lengths, and export packaging (tube/box/pallet) upon request.

Do your filler rods come with certification documents?

Absolutely. We provide COA, MSDS, RoHS, REACH, and CE certificates upon request.

What's the difference between TIG rod and MIG wire?

TIG rods are solid cut-length wires used for manual TIG (GTAW) welding. MIG wires come on spools and are continuously fed during MIG welding.

Are filler rod and TIG rod the same thing?

In most cases, yes. "Filler rod" is a general term, while "TIG rod" refers specifically to filler material used in TIG welding.

What does "ER” mean in filler rod designation?

ER” stands for Electrode or Rod. In TIG welding, the rod is fed manually, but the designation still follows AWS ER classifications (e.g., ER4043).

How to choose 4043 and 5356 filling rods

When welding 6XXX series aluminum or 5XXX series aluminum with less than 3% magnesium, 4043 and 5356 aluminum filler rods are both common choices. They both meet high shear strength requirements and provide excellent performance in most aluminum alloy welding applications. However, depending on the specific application requirements, they each have unique advantages in different scenarios.

4043 Aluminum Filler Rod is suitable for the following applications:

• It has excellent high temperature crack resistance when exposed to high temperature environment for a long time (above 150°F).
• Applications that wish to reduce the risk of termination and shrinkage cracking, provide more stable welds and reduce welding defects.
• Welding tasks that require high weld aesthetics can produce bright and clean weld appearance.
• Workpieces that are particularly sensitive to welding deformation can minimize the deformation problems caused by welding.

5356 Aluminum Filler Rod is suitable for the following applications:

• When welding 5XXX or 6XXX series aluminum, higher tensile strengths can be achieved for high strength requirements.
• The base material after anodizing treatment needs to have a good color match, and the weld should have excellent color consistency with the base material.
• In application scenarios that withstand dynamic loads, it provides higher ductility and toughness to ensure the reliability of the welded structure.
• In connection situations where higher shear strength is required, only one welding is required to achieve higher shear strength.

How to choose welding materials correctly