The Harris ER5356 TIG Welding Rod (3/32 in diameter, 36 in lengths, 10 lb tube) is a magnesium-alloyed aluminum filler rod designed for TIG (GTAW) welding of 5xxx-series and 6xxx-series aluminum base alloys. ER5356 is the highest-strength commonly available aluminum TIG filler: its nominal tensile strength of 40,000 psi (276 MPa) as-deposited exceeds ER4043 by approximately 15%, making it the preferred choice wherever structural strength, fatigue resistance, or post-weld anodizing color match are priorities. The 3/32 in diameter threads cleanly through a standard TIG torch holder and covers a wide range of aluminum plate thicknesses from 3/32 in through 3/8 in in a single pass or multi-pass sequence.
| Specification | Value |
|---|---|
| Manufacturer | Harris Products Group |
| AWS Classification | ER5356 (AWS A5.10 / A5.10M) |
| Diameter | 3/32 in (2.4 mm) |
| Length | 36 in (914 mm) |
| Package Weight | 10 lb (4.5 kg) tube |
| Base Alloy Composition | Al–5% Mg (balance aluminum) |
| Tensile Strength (as-deposited) | 40,000 psi (276 MPa) minimum |
| Yield Strength | 28,000 psi (193 MPa) minimum |
| Elongation | 17% minimum |
| Recommended Process | GTAW (TIG); also usable as GMAW (MIG) wire in spool form |
| Polarity | AC (preferred for aluminum TIG) |
| Shielding Gas | 100% Argon |
| Preheat | Not required for most alloys; 200–300°F (93–149°C) for thick castings |
| Compatible Base Alloys | 5052, 5083, 5086, 5454, 5456, 6061, 6063, 6082, 7005 |
Source: Harris Products Group ER5356 data and AWS A5.10/A5.10M Aluminum Welding Electrode and Rod Standard.
- Marine & Boat Building: Hull panels (5083, 5086), aluminum fuel and water tanks, topsides and deck fittings. ER5356's magnesium content provides resistance to salt-water corrosion and matches the color of 5xxx-series alloys after anodizing — critical for cosmetic applications above the waterline.
- Structural Aluminum Fabrication: Structural members, brackets, trailers, livestock and utility trailer frames in 5052 and 6061. The 40 ksi tensile rating meets most structural aluminum code requirements per AWS D1.2 Structural Welding Code — Aluminum.
- Motorsport & Automotive: Roll bar gussets, fuel cell housings, aluminum pedal boxes, and tube chassis nodes in 6061-T6. ER5356 is recommended when the weld area will be anodized because it produces a brighter, more consistent anodized finish than ER4043.
- Pressure Vessels & Cryogenics: ER5356 maintains acceptable toughness at cryogenic temperatures (down to −196°C / −320°F), making it suitable for liquid nitrogen, liquid oxygen, and LNG vessel fabrication per ASME Section IX.
- Aerospace Ground Support: Aluminum tooling fixtures, ground support equipment, and non-flight structural aluminum fabricated to civil or military standards where ER5356's higher strength over ER4043 is specified.
These are the two most common aluminum TIG filler rods — choosing between them correctly affects weld strength, cracking resistance, and finish:
| Property | ER5356 (this rod) | ER4043 |
|---|---|---|
| Tensile strength | 40,000 psi min | 27,000 psi min |
| Silicon content | Low (<0.25%) | High (~5%) |
| Hot-cracking sensitivity | Low on 5xxx alloys; higher risk on 6xxx with high dilution | Very low — excellent crack resistance on 6061, 6063 |
| Anodizing result | Bright, good color match to 5xxx | Gray/dark — poor anodizing appearance |
| Fluidity | Good | Excellent (flows more easily) |
| Best for | 5xxx alloys, structural, anodized parts, cryogenic | 6xxx alloys (6061, 6063), casting repair, general-purpose |
See sibling ER5356 sizes: Harris ER5356 1/8 in × 36 in 10 lb tube. Browse the full TIG rod collection for all aluminum filler options. Pair with the Lincoln Aspect 230 or Precision TIG 225 for a complete AC TIG aluminum setup.
Should I use ER5356 or ER4043 for welding 6061 aluminum?
ER4043 is generally recommended for 6061 aluminum because high-silicon ER4043 reduces the risk of hot cracking that can occur when welding 6061 (which contains magnesium and silicon). If post-weld anodizing is required and strength is more important than crack resistance, ER5356 can be used on 6061 at low dilution and with proper joint preparation. Consult AWS D1.2 Table 4.5 or the base metal manufacturer's recommendation when welding procedure qualification is required.
Can I use ER5356 to weld 7075 aluminum?
7075 is a high-zinc, high-strength aluminum alloy that is generally considered unweldable by arc welding methods due to extreme susceptibility to stress-corrosion cracking in the weld HAZ. Neither ER5356 nor any other standard filler is recommended for structural welds on 7075-T6. Consult the base metal supplier and AWS D1.2 for guidance on specific applications.
What tungsten electrode do I use with ER5356 for AC TIG?
Use a pure tungsten (green band) or rare-earth/Tri-Mix tungsten electrode on AC. A 1/8 in diameter electrode (like the Lincoln Tri-Mix 1/8 in) pairs well with the 3/32 in ER5356 filler rod at current ranges typical for 1/8–3/16 in aluminum plate. Allow the AC arc to form a small hemispherical ball on the tungsten tip — this is correct for AC aluminum welding.
Why does ER5356 produce a brighter finish after anodizing than ER4043?
Anodizing aluminum creates an aluminum oxide layer by electrochemical oxidation. High-silicon fillers like ER4043 develop a gray or dark appearance after anodizing because silicon does not anodize the same way as pure aluminum. The magnesium-based ER5356 has minimal silicon, so the weld deposit anodizes to a color much closer to the base metal — important for any application where welded areas will be visible after anodizing (marine fittings, architectural aluminum, motorsport bodywork).