Welding 5052 Aluminum

Welding 5052 aluminum is not difficult, but it does require some specific knowledge and equipment.

This article provide step by step information for welding 5052 aluminum succesfully using TIG, MIG and Brazing. But before let us understand the metallurgy of 5052 Aluminum.

5052 aluminum is an aluminum alloy with magnesium as the primary alloying element. With a density of 2.68 g/cm3 and melting point of 605 °C, it is also one of the lightest alloys in commercial use.

The strength of 5052 aluminum alloy varies depending on the temper (most common tempered grade is 5052-H32), but it is generally stronger than that of most other common alloys. It also has excellent corrosion resistance, making it well suited for use in outdoor applications.

5052 Aluminum chemical composition

5052 Aluminum is an alloy that contains magnesium, chromium and other metals. 5052 Aluminum mainly composed of 2.2- 2.8% magnesium, 0.15- 0.35% chromium and approx 97% aluminum with other minor alloying elements. Its chemical composition makes it highly resistant to corrosion.

Below table list the chemical compostion of 5052 aluminum according to the BS 573-3 standard.

Element % Wt.
Manganese 0.10 max.
Iron 0.40 max.
Copper 0.10 max.
Magnesium 2.20 – 2.80
Silicon 0.25 max.
Zinc 0.10 max.
Chromium 0.15 – 0.35
Others 0.15 max.
Aluminium Balance

5052 Aluminum Mechanical Properties

The mechanical properties of 5052 aluminum depend on the tempering process of the metal. In the annealed state, it is soft and ductile.

However, if it undergoes a cold-working process, it becomes much harder. The yield strength of 5052 aluminum is around 130 MPa, while its ultimate tensile strength is around 210- 260 MPa.

Property Value
Tensile Strength Ksi,(MPa) 30 -37.5 (210 – 260)
Proof Stress Ksi,(MPa) minimum 19 (130)
Brinell Hardness (HB) 61

5052 Aluminum Welding Rod

Best Filler wire rod for welding 5052 aluminum is ER5654 as per AWS A5.10 specification. ER5654 gives matching weld metal properties with good color match for welding using TIG or MIG process.

Silicon +IronMagnesiumAluminumManganeseZirconiumCopperChromiumTitaniumOther each & Total
0.45 max.3.1 to 3.9balance0.01 max.0.20 max.0.05 max.0.15 to 0.350.05 to 0.150.05 (0.15)
ER5654 Chemical Compositions (AWS A5.10)

Other filler wires such as ER4043 and ER5356 can also be used for welding 5052 aluminum but they are mainly used and beneficial for welding 5052 grade with other aluminum grades.

Download below chart to easily find suitable welding filler wire rod for any aluminum grade.

Click here to Download Aluminum Filler wire Selection Chart..

TIG Welding 5052 Aluminum

When welding 5052 aluminum, it’s important to use a filler rod that has the same composition as the base metal. ER5654 is the matching TIG filler wire for welding 5052 grade aluminum.

Welding 5052 Aluminum

Here are some tips and tricks for TIG welding 5052 aluminum:

– Use ER5654 filler wire rod. This type of rod is specifically designed for welding aluminum, and will give you the best results.

– Use AC polarity. This will help prevent the formation of oxides on the surface of the weld.

– Weld with pure argon or argon helium gas mix. This will help to prevent oxidation of the weld area.

– Use high heat for thicker material. This will help to ensure that the weld penetrates completely through the thickness of the metal.

MIG Welding 5052 Aluminum

MIG welding 5052 can be made using AC polarity of DCEP polarity welder. Follow below steps for MIG welding 5052 aluminum grade:

1. Use ER5654 wire spool for welding. Make sure weld surface is free from moisture.

2. Set your welder to AC and use an argon or Argon-helium mix for the gas. This will help reduce oxide formation on the weld.

3. Use a higher power setting when welding aluminum. This will compensate the heat disspitation losses due to higher thermal conductivity of aluminum.

4. When starting the weld, use a short arc length and move quickly along the edge of the metal. This will help prevent “burn through” of the thin aluminum sheet.

Welding 5052 Aluminum to 6061

Welding 5052 Aluminum to 6061 can be achieved through the use of an ER5356 TIG-MIG filler wire rod.

For TIG welding 5052 Aluminum to 6061, use AC polarity and pure argon gas shielding with ER5356 wire.

For MIG welding 5052 Aluminum to 6061, use AC polarity or DCEP polarity and pure argon gas shielding. Make sure surface is free from contaminiation otherwise you will face issue of welding porosity.

Welding 5052 Aluminum to 4043

Welding 5052 Aluminum to 4043 can be done using an ER4043 TIG-MIG filler wire rod. ER4043 TIG-MIG filler wire rod is designed for welding aluminum. It has a lower melting point than ER5052 aluminum.

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