The Harris AZ61T60 is an AZ61A magnesium TIG welding rod classified ERAZAl per AWS A5.19/A5.19M for the GTAW process. Packaged as 1/8 in (3.2 mm) diameter, 36-inch lengths in a 3 lb box, it is engineered for welding wrought alloys and cast magnesium alloy components. Harris Products Group, a Lincoln Electric company, manufactures this filler to precise chemistry specifications matching the AZ61A alloy system. WeldingMart is an authorized Harris distributor.
Magnesium rapidly oxidizes in air, which makes welding magnesium alloys significantly more challenging than aluminum or steel. The AZ61A composition — approximately 6% aluminum and 1% zinc — produces a welding alloy that matches the chemistry of many common wrought magnesium base metals, maintaining joint strength and corrosion resistance while the shielding gas protects the molten pool from atmospheric oxidation.
| Specification | Value |
|---|---|
| AWS Classification | ERAZAl / AZ61A (AWS A5.19) |
| Harris Part Number | AZ61T60 |
| Diameter | 1/8 in (3.2 mm) |
| Length | 36 in (914 mm) |
| Package | 3 lb (1.4 kg) box |
| Al content | 5.8–7.2% |
| Zn content | 0.4–1.5% |
| Mn content | 0.15% min |
| Process | GTAW (TIG) |
| Polarity | ACHF (AC High Frequency) or DCEN |
| Shielding Gas | 100% Argon (high purity, 99.997%+) |
| Base Metals | AZ61A, AM100A, and similar wrought magnesium alloys |
AWS A5.19 covers magnesium alloy welding rods and electrodes. Technical data available at harriswelding.com. Published AWS standards: aws.org/standards.
- Aerospace and aviation: Repair welding magnesium aircraft components, gearbox housings, and structural castings per AS/NAS maintenance specifications.
- Automotive and motorsport: Welding magnesium transmission cases, intake manifolds, and lightweight structural brackets in performance vehicles.
- Industrial repair of magnesium castings: Repair of wrought alloys and cast magnesium housings in industrial equipment, compressors, and power tools.
- Consumer electronics and portable equipment: Welding magnesium alloy laptop chassis, camera bodies, and handheld tool housings requiring lightweight structural repairs.
- Specialty fabrication: Custom magnesium structural components for high-performance applications where the weight-to-strength ratio of magnesium outperforms aluminum.
Magnesium alloys require AC (ACHF) for TIG welding because the AC cycle breaks up and removes the tenacious magnesium oxide layer on the surface. This "cleaning action" is the same principle used for TIG welding aluminum. Without it, the oxide film prevents fusion and causes contamination in the weld pool.
| Parameter | AZ61A Magnesium TIG (1/8 in rod) |
|---|---|
| Polarity | ACHF (AC with high frequency) |
| Shielding Gas | 100% Argon (99.997%+ purity) |
| Flow Rate | 20–35 CFH (use back purge for tube/pipe) |
| Tungsten | Pure (green) or Zirconiated (white), 1/8 in dia, balled tip |
| Amperage (typical) | 120–200 A (ACHF, 1/8 in rod) |
| Preheat | 300–400 °F (149–204 °C) for castings; minimal for wrought |
| Interpass temp | Do not exceed 400 °F |
| Base metal prep | Chemical clean or mechanical — oxide removal is critical |
Magnesium rapidly oxidizes, so pre-cleaning is essential. Use a clean stainless steel wire brush (dedicated to magnesium only) followed by a wipe with acetone or methyl ethyl ketone (MEK). During welding, maintain shielding gas coverage aggressively — any lapse causes rapid reoxidation. Use a larger gas cup (No. 8–10) and higher flow rates than you would for steel or aluminum.
Magnesium welding rod is sensitive to surface oxidation and moisture. Store Harris AZ61T60 rods in their original sealed packaging. Key handling guidelines:
- Store in dry conditions at 40–80 °F — magnesium alloys are susceptible to stress-corrosion cracking in humid environments
- Handle with clean cotton gloves to prevent skin-oil contamination that increases porosity
- Do not store in contact with aluminum or steel tools — galvanic contact in humid conditions causes corrosion
- Discard rods showing heavy gray-white oxidation — surface oxide contamination cannot be fully removed by brushing alone
- Keep fire suppression materials on hand: magnesium burns with extreme intensity and water MUST NOT be used to extinguish a magnesium fire (use dry sand or Class D extinguishers)
AZ61A magnesium TIG welding requires an AC-capable TIG machine. Lincoln Electric AC/DC TIG machines including the Square Wave TIG 200 and Aspect 375 provide the ACHF output required. Balance control (ACHF balance adjustment) should be set to allow adequate cleaning action while managing tungsten overheating — typically 65–75% electrode negative balance. Use pure argon shielding gas at 99.997% minimum purity; impure gas causes oxidation of the magnesium weld pool even at small trace amounts.
See also: Harris AZ92A Magnesium TIG Rod 3/32 in, Harris AZ92A Magnesium TIG Rod 1/8 in, and all welding wire.
- What is the difference between AZ61A and AZ92A magnesium welding rod?
- AZ61A (ERAZAl) contains 6% aluminum / 1% zinc and is primarily used for welding wrought AZ61A magnesium alloy sheet and extrusions. AZ92A (ERAZAl per AWS A5.19) contains 9% aluminum / 2% zinc and is better suited for cast magnesium alloys (AZ92A, AM100A, and similar). Match the filler to your base metal chemistry for best results.
- Do I need AC to TIG weld magnesium?
- Yes. ACHF (AC High Frequency) is required for TIG welding magnesium. The AC cleaning cycle removes the refractory magnesium oxide layer that prevents fusion. DCEN alone does not provide oxide cleaning and results in poor fusion and contamination. Use a TIG machine with adjustable balance control for best results.
- What shielding gas is required for magnesium TIG welding?
- 100% Argon at high purity (99.997% or better) is the required shielding gas. Magnesium rapidly oxidizes — even trace amounts of oxygen or moisture in shielding gas cause visible oxide contamination. Use a dedicated regulator for magnesium work to avoid cross-contamination with other gases.
- Why is magnesium welding considered hazardous?
- Magnesium burns with an intense white flame at temperatures exceeding 3,100 °F (1,700 °C) and reacts violently with water. Welding magnesium produces hazardous fumes and fine magnesium particles that are flammable. Follow OSHA standards for fume ventilation, fire prevention, and Class D fire extinguisher placement. Never use water, CO₂, or halon extinguishers on a magnesium fire.
- Can I weld AZ61A to AZ91D cast magnesium?
- Yes, with caution. AZ61A filler is slightly lower in aluminum than AZ92A, which may reduce strength on higher-aluminum cast alloys. For dissimilar magnesium alloy joints, AZ92A filler is often preferred as a more universal option. Consult the base metal manufacturer for qualified WPS (welding procedure specification) requirements.
- How do I prepare magnesium for TIG welding?
- Remove the oxide layer by mechanical cleaning (dedicated stainless steel brush or file) followed by solvent wiping with acetone or MEK. For castings, chemical etching (5% chromic acid) may be needed to remove deeply embedded oxide. Weld immediately after cleaning — magnesium re-oxidizes within minutes of exposure to atmosphere.
- What tungsten do I use for magnesium TIG welding?
- Use pure tungsten (green band) or zirconiated tungsten (white/white-yellow band), sized 3/32–1/8 in for typical magnesium work. The AC current creates a ball end on the tungsten tip naturally — do not grind to a point. Set your machine's balance control to 65–75% EN (electrode negative) to balance cleaning action with tungsten protection.
Harris AZ61T60 provides AZ61A magnesium TIG welding rod at 1/8 in x 36 in in a 3-piece package — the general-purpose magnesium filler for welding wrought and cast magnesium alloys containing 5–7% aluminum. AZ61A (AWS A5.19 ERAZ61A classification) is the second most commonly specified magnesium TIG rod after AZ92A, and it is the preferred filler for AZ31, AZ61, and mixed-alloy magnesium structural work where AZ92A's higher aluminum content would cause over-alloying and cracking risk.
| Property | AZ61A Value |
|---|---|
| AWS Classification | ERAZ61A (AWS A5.19) |
| Aluminum Content | 5.8–7.2% |
| Zinc Content | 0.40–1.5% |
| Manganese | 0.15% min |
| Magnesium | Balance |
| Tensile Strength (as-welded) | ≥ 35,000 psi |
| Yield Strength | ≥ 18,000 psi |
| Elongation | ≥ 10% |
| Melting Range | 905–1,105 °F (approximate) |
The lower aluminum content (6% vs. 9% in AZ92A) gives AZ61A a wider freezing range and better crack resistance in higher-zinc base metals. AZ61A is the appropriate filler when welding AZ31B sheet and extrusion (3% Al, 1% Zn) where over-alloying from AZ92A filler could produce a brittle HAZ. It is also appropriate for AZ61 extrusions and roll cages, aircraft skin repair, and structural magnesium fabrication where weld ductility is prioritized over absolute strength.
| Parameter | AZ61A 1/8 in TIG |
|---|---|
| Current | AC (mandatory for magnesium) |
| Amperage | 90–150 A |
| Shielding Gas | 100% Argon, 15–25 CFH |
| Electrode | Pure or zirconiated tungsten (1/8 in balled tip) |
| Preheat | 250–400 °F for castings > 3/16 in; wrought alloys often weld cold |
| Interpass Temp | ≤ 450 °F |
| Post-weld | Slow cool; stress relief at 300–350 °F for 1 hour on restrained joints |
AZ61A requires AC TIG exactly as AZ92A does — the AC cleaning action breaks the high-melting magnesium oxide (MgO) film that forms on molten magnesium. Without AC, the oxide prevents fusion. Most modern AC TIG inverters (Lincoln Square Wave, Miller Dynasty, Fronius Magic Wave) provide adjustable AC balance — set 60–70% cleaning for AZ61A wrought sheet; 50–60% penetration-biased for thicker castings where fusion depth is more critical.
AZ61 extrusion tubing is used in high-performance bicycle frames, racing vehicle components, and aerospace structural applications where the weight savings of magnesium over aluminum are justified. Repairing AZ61 extrusion tubing with AZ61A filler requires:
- Clean joint surfaces thoroughly (stainless brush + acetone wipe)
- Tightly fitted joints — magnesium does not bridge large gaps well in TIG welding
- Uniform preheating of the extrusion section (wrapping in heat tape or short torch preheat) to bring tube to 200–300 °F before tacking on thin-wall tube
- Multiple short passes with immediate slow cooling to prevent hot cracking at tube-to-tube joints
- Post-weld inspection — visible oxide inclusion lines ("cold shut" appearance) indicate inadequate AC cleaning; increase AC balance toward cleaning and re-weld
Not all magnesium alloys are weldable. Alloys containing more than 1.5–2% zinc are prone to weld hot cracking due to low-melting eutectic formation. The AZ series (Al-Zn) is generally weldable with proper procedure. The ZK, ZE, and EZ series (high zinc, rare earth) are difficult or unweldable. Always verify alloy designation before beginning magnesium TIG repair:
- Weldable: AZ10A, AZ31B, AZ61A, AZ63A, AZ80A, AZ92A, AM100A, EK41A, LA141A, ZE41A
- Weld with caution (qualified procedure required): AZ80A (high strength/crack risk), HM21A, HM31A
- Generally not weldable by fusion: ZK60A, ZK40A, ZH62A (high zinc; solidification cracking)
Harris AZ61T60 is an authorized WeldingMart product. See also Harris AZ92A 1/8 in TIG Rod for high-aluminum casting alloys, and all welding wire and rod products.
Harris AZ61T60 provides AZ61A magnesium TIG welding rod at 1/8 in x 36 in in a 3-piece package — the general-purpose magnesium filler for welding wrought and cast magnesium alloys containing 5–7% aluminum. AZ61A (AWS A5.19 ERAZ61A classification) is the second most commonly specified magnesium TIG rod after AZ92A, and it is the preferred filler for AZ31, AZ61, and mixed-alloy magnesium structural work where AZ92A's higher aluminum content would cause over-alloying and cracking risk.
| Property | AZ61A Value |
|---|---|
| AWS Classification | ERAZ61A (AWS A5.19) |
| Aluminum Content | 5.8–7.2% |
| Zinc Content | 0.40–1.5% |
| Manganese | 0.15% min |
| Magnesium | Balance |
| Tensile Strength (as-welded) | ≥ 35,000 psi |
| Yield Strength | ≥ 18,000 psi |
| Elongation | ≥ 10% |
| Melting Range | 905–1,105 °F (approximate) |
The lower aluminum content (6% vs. 9% in AZ92A) gives AZ61A a wider freezing range and better crack resistance in higher-zinc base metals. AZ61A is the appropriate filler when welding AZ31B sheet and extrusion (3% Al, 1% Zn) where over-alloying from AZ92A filler could produce a brittle HAZ. It is also appropriate for AZ61 extrusions and roll cages, aircraft skin repair, and structural magnesium fabrication where weld ductility is prioritized over absolute strength.
| Parameter | AZ61A 1/8 in TIG |
|---|---|
| Current | AC (mandatory for magnesium) |
| Amperage | 90–150 A |
| Shielding Gas | 100% Argon, 15–25 CFH |
| Electrode | Pure or zirconiated tungsten (1/8 in balled tip) |
| Preheat | 250–400 °F for castings > 3/16 in; wrought alloys often weld cold |
| Interpass Temp | ≤ 450 °F |
| Post-weld | Slow cool; stress relief at 300–350 °F for 1 hour on restrained joints |
AZ61A requires AC TIG exactly as AZ92A does — the AC cleaning action breaks the high-melting magnesium oxide (MgO) film that forms on molten magnesium. Without AC, the oxide prevents fusion. Most modern AC TIG inverters (Lincoln Square Wave, Miller Dynasty, Fronius Magic Wave) provide adjustable AC balance — set 60–70% cleaning for AZ61A wrought sheet; 50–60% penetration-biased for thicker castings where fusion depth is more critical.
AZ61 extrusion tubing is used in high-performance bicycle frames, racing vehicle components, and aerospace structural applications where the weight savings of magnesium over aluminum are justified. Repairing AZ61 extrusion tubing with AZ61A filler requires:
- Clean joint surfaces thoroughly (stainless brush + acetone wipe)
- Tightly fitted joints — magnesium does not bridge large gaps well in TIG welding
- Uniform preheating of the extrusion section (wrapping in heat tape or short torch preheat) to bring tube to 200–300 °F before tacking on thin-wall tube
- Multiple short passes with immediate slow cooling to prevent hot cracking at tube-to-tube joints
- Post-weld inspection — visible oxide inclusion lines ("cold shut" appearance) indicate inadequate AC cleaning; increase AC balance toward cleaning and re-weld
Not all magnesium alloys are weldable. Alloys containing more than 1.5–2% zinc are prone to weld hot cracking due to low-melting eutectic formation. The AZ series (Al-Zn) is generally weldable with proper procedure. The ZK, ZE, and EZ series (high zinc, rare earth) are difficult or unweldable. Always verify alloy designation before beginning magnesium TIG repair:
- Weldable: AZ10A, AZ31B, AZ61A, AZ63A, AZ80A, AZ92A, AM100A, EK41A, LA141A, ZE41A
- Weld with caution (qualified procedure required): AZ80A (high strength/crack risk), HM21A, HM31A
- Generally not weldable by fusion: ZK60A, ZK40A, ZH62A (high zinc; solidification cracking)
Harris AZ61T60 is an authorized WeldingMart product. See also Harris AZ92A 1/8 in TIG Rod for high-aluminum casting alloys, and all welding wire and rod products.
AZ61A magnesium welding alloy meets AWS A5.19 classification requirements for ERAZ61A, with rigidly controlled manufacturing ensuring consistent chemistry across all rods in the 3-piece box. The alloy is formulated for welding wrought alloys including AZ31, AZ61, and similar composition base metals where a mid-range aluminum content (6%) provides a balance of strength and crack resistance. For wrought alloys in sheet and extrusion form, AZ61A verifies compatible chemistry with the most commonly used aerospace and automotive magnesium alloy systems.
Before welding, always clean surfaces thoroughly — magnesium oxide forms rapidly on magnesium and blocks fusion if not removed. Stainless steel wire brush and acetone degreasing of edges adjacent to the weld zone is the minimum preparation for good weldability. The weld pool area must be cleaned of all oxide before tacking. Edges adjacent to the joint should be free of all oxide, oil, and moisture. Failure to clean surfaces results in oxide inclusion lines and weld prior cracking due to trapped contaminants.
AZ61A has good weldability across the range of wrought alloys, and similar filler metals with different aluminum levels (AZ31 and AZ92A) are available for over- and under-alloyed base metal situations. The melted pool of magnesium behaves similarly to aluminum — fluid and fast-solidifying — so technique must be adapted accordingly. A small shop with occasional magnesium repair needs will find the 3-piece box format appropriate; the website listing confirms the 3-piece / 1/8 in / 36 in specification. Cracks in completed welds most commonly result from oxide contamination or rapid cooling — post-weld slow cooling eliminates cooling-rate induced cracks on restrained joints.
WeldingMart is proud to offer Harris AZ61A magnesium TIG welding rod. Add to cart to order the 3-piece box (1/8 in x 36 in). It is important to verify alloy compatibility before welding — AZ61A is the appropriate filler for AZ31, AZ61, and similar wrought alloys. For high-aluminum AZ92A castings, AZ92A filler is the better choice. Joining wrought magnesium sheet and extrusions with AZ61A TIG rod is an important step in aerospace repair, custom fabrication, and OEM component rework that require reviewed procedures per AWS D1.2 or equivalent aerospace specifications.
The melted pool of AZ61A magnesium conforms to the joint geometry quickly due to magnesium's low surface tension in the molten state. Reviewed alongside other magnesium fillers, AZ61A offers the best balance of crack resistance and strength for wrought alloy applications. After welding, the melted and re-solidified zone should conform to the original surface profile — any raised crown or cavity indicates a travel speed or technique issue. It is important to practice on scrap magnesium before attempting production joining, as the AC TIG arc behavior on magnesium is different from steel or aluminum. Review the parameter table in Section 3 of this page and conform to the setup recommendations for best results. WeldingMart's technical team is available by phone or email to offer guidance on AZ61A selection and joining procedure for specific magnesium base metal applications.