Proceedings of the Institution of Mechanical

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Effect of ER4043 and ER5356 filler wire on mechanical properties and microstructure of dissimilar
aluminium alloys, 5083-O and 6061-T6 joint, welded by the metal inert gas welding
Rajesh P Verma, KN Pandey and Yogesh Sharma
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture published online 17
June 2014
DOI: 10.1177/0954405414535771

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Original Article

Proc IMechE Part B:

J Engineering Manufacture
1–8
Effect of ER4043 and ER5356 filler wire Ó IMechE 2014
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DOI: 10.1177/0954405414535771

microstructure of dissimilar aluminium pib.sagepub.com

alloys, 5083-O and 6061-T6 joint,

welded by the metal inert gas welding

Rajesh P Verma1, KN Pandey2 and Yogesh Sharma1

Abstract
This work studies the effect of filler metal on the mechanical and microstructure properties of dissimilar aluminium
alloys of 5083-O and 6061-T6 welded using metal inert gas welding. The metal inert gas welding was used because it is
widely being used for joining aluminium alloys for aerospace, marine, automotive and many other application of commer-
cial importance. The joints were fabricated using filler metals ER4043 and ER5356. Both welded samples were cut
according to ASTM B-557M to obtain the tensile strength, and Vickers hardness was measured at welded metal, heat-
affected zone and base metal. The mechanical properties of welded samples were analysed by using micrographs
obtained from optical microscopy. From the results, the filler metals ER5356 were more able to enhance the mechanical
properties and microstructure characteristics of the welded samples.

Keywords
Dissimilar aluminium alloys, metal inert gas welding, 6061-T6, 5083-O, ER 4043, ER 5356

Date received: 4 September 2013; accepted: 23 April 2014

Introduction alloys are easily welded by conventional arc welding

Magnesium-based aluminium alloys (Al–Mg alloy) are
non-heat treatable alloys with medium strength, high
ductility, excellent corrosion resistance and weldability.
Wrought Al–Mg alloys are used as structural materials
in marine, automotive, aircraft and cryogenic applica-
tions. These materials exhibit their strength mainly
from solid solution strengthening by Mg, which has a
substantial solid solubility in aluminium.1 Al–Mg–Si
alloy, one of the widely used heat-treatable alloys, is
choice for medium-to-high-strength requirements and
has good toughness characteristics. The major alloying
elements magnesium (Mg) and silicon (Si) increase the
strength of the alloy through precipitation hardening.
These types of alloys are also age hardenable and usu-
ally heat-treated to T4 (natural ageing) and T6 (artifi-
cially ageing) temper conditions to develop required
strength. Al–Mg–Si alloys are widely used in transpor-
tation components, machinery equipments, recreational
products and consumer durables.2
For aluminium alloy, the most common joining
method is fusion welding. Generally, 5xxx and 6xxx
processes, metal inert gas (MIG) welding and tungsten
inert gas (TIG) welding.3 However, some important
characteristics, such as solidification cracking, porosity,
heat-affected zone (HAZ) degradation and so on must
be considered during welding, due to the greater
amount of alloying elements used in commercial
alloys.4 Solidification cracking is intergranular, that is,
along the grain boundaries of the weld metal, and it
occurs during the terminal stage of solidification, when
the tensile stresses developed across the adjacent grains
exceed the strength of the completely solidified weld
metal. The solidifying weld metal tends to contract
1
Department of Mechanical Engineering, Graphic Era University (GEU),
Dehradun, India
2
Department of Mechanical Engineering, Motilal Nehru National Institute
of Technology (MNNIT), Allahabad, India
Corresponding author:
Rajesh P Verma, Department of Mechanical Engineering, Graphic Era
University (GEU), 566/6, Bell Road, Clement Town, Dehradun, 248002,
India.
Email: rajesh_diva1@yahoo.in

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2 Proc IMechE Part B: J Engineering Manufacture
because of both solidification shrinkage and thermal
contraction. The surrounding base metal also tends to
contract, but not as much, because it is neither melted
nor heated as much the weld metal. Therefore, the con-
traction of the solidifying metal can be hindered by the
base metal results in solidification cracking. It is found
that fine equiaxed grains are often less susceptible to
solidification cracking than coarse columnar grains. If
the copper (Cu) content of weld metal is raised suffi-
ciently, solidification cracking can be significantly
reduced. Minor alloying elements (Fe, Si, etc.) have
also been found to reduce the solidification cracking
susceptibility of aluminium alloys.5 Severe liquation or
hot cracking can occur in the HAZ during welding.
The tendency of hot cracking depends on the chemical
composition of the alloy. The alloys of the 6xxx series
alloys are, for instance, more sensitive to hot cracking
than the alloys of the 5xxx series. Porosity forms when
hydrogen gas is entrapped during solidification as it is
highly soluble in molten aluminium. Hydrogen gas
solubility in the solid is less than in liquefied phase of
aluminium, so hydrogen is rejected from solid to
melted material, causing localized super saturation,
bubble nucleation and growth.6 Increase in porosity is
generally associated with high humidity and poor sur-
face preparation. Use of suitable inert gases to shield
the weld pool can reduce porosity.7
The welding parameters and type of filler metal
strongly affect the mechanical properties of weldment.
A study of the mechanical properties of welded plates
of commercial 6061-T6 aluminium alloy with a thick-
ness of 12.7 mm was made by Ambriz et al.8 In this
study, a filler wire ER 40433 of diameter 1.2 mm was
employed to fabricate the single V-groove joint at cur-
rent 210 A and voltage 23 V. The effect of the welding
profile generated by the modified indirect electric arc
technique on the fatigue behaviour of 6061-T6 alumi-
nium alloy of thickness 9.5 mm was investigated using
ER 4043 filler wire of 1.2 mm diameter, 230 A current
and 24 V voltage by Ambriz et al.9 in another work. An
investigation by Ahmad and Bakar10 was done on gas
metal arc welded 6061 aluminium alloys with a thick-
ness of 10 mm to investigate the effect of post-weld heat
treatment on the mechanical and microstructure prop-
erties. The filler used for the welding process was ER
4043 with a diameter of 1.2 mm, and welding current of
210 A, voltage of 24 V, air flow of 23.6 L/min and
travel speed of 3.6 mm/s were used for fabrication of
the joints in this work. Kuk et al.7 investigated the
effects of temperature and shielding gas mixture on fati-
gue life of 5083 aluminium alloy of thickness 12 mm
welded by Al5183-WY welding wire of 1.2 mm dia-
meter at 220 A current, 21 V, 23 V, 26 V and 29 V vol-
tage with 30–50 cm/min speed. The literatures7–17
suggest that filler metal ER4043 is more appropriate for
welding of 6xxx aluminium alloys and filler metal
ER5356 is more appropriate for 5xxx aluminium alloys.
Arc welding of aluminium alloys of different compo-
sition (dissimilar alloys) gives problem due to difference
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in thermal conductivity. The heat produced by the arc
will flow easily in the material with the large thermal
conductivity. This can result in lack of fusion of this
material or excessive melting of the material with the
lower thermal conductivity. There are only few works
available on fusion welding of dissimilar aluminium
alloys. Luijendijk11 investigated the welding perfor-
mance, hot tearing tendency and mechanical properties
of gas tungsten arc (GTA) welded dissimilar aluminium
alloys of the series 5xxx (Al–Mg) and 6xxx (Al–Mg–
Si). Four material combinations, AA5083 O–AA5754
H32, AA5083 O–AA6060 T6, AA5083 O–AA6061 T6
and AA6082 T6–AA6060 T6, were examined to the
asymmetry of the weld and melting behaviour of the
different weld grooves. The weld materials used in the
welding of the four material combinations were
ER5356, ER5356 and ER4043, ER5356 and ER4043,
ER5356 and ER4043, respectively. The technique to
realize a good weld for a combination of 5xxx and
6xxx materials were analysed in respect of groove melt-
ing and weld penetration. Mechanical properties of the
welds for the different material thickness were also
investigated. The proper selection of filler material for
dissimilar aluminium alloys joint is essential for the
strong weldments. In this work, the effect of two filler
materials, ER 4043 and ER 5356 on the microstructure
and mechanical properties of MIG-welded dissimilar
aluminium alloys (5083-O and 6061-T6 combination)
was examined, and an attempt is made to explain the
static mechanical properties of the joint in context of
microstructure.
Experimental work
The plates of aluminium alloys (5083-O and 6061-T6)
were cut into the required sizes (300 3 150 3 8 mm3)
by cutting and grinding with a power hacksaw. Single
‘V’ butt joint configuration was prepared to MIG-
welded joints of dissimilar alloys as shown in
Figure 1(a). Single-pass welding procedure was applied
to make the joints. Two types of samples were fabri-
cated: one using ER 4043 filler wire and another using
ER 5356 filler wire. High-purity argon gas was used as
shielding gas. The chemical composition of base metals
and filler metals are presented in Table 1. The welding
conditions and process parameters presented in Table 2
were used to make the joints. The welding torch was
kept above the edge of 6061-T6 plate for better weld-
ments during welding as the thermal conductivity of
6061-T6 alloy is more than 5083-O alloy.
Tensile specimens were prepared to obtain ultimate
tensile strength and percentage of elongation (fracture
strain). Procedures prescribed by the ASTM B-557M
standard were followed for the preparation of the
transverse tensile specimens.19 The specimens are
machined perfectly into the specified dimensions, as
shown in Figure 1(b), by a computer numerical control
(CNC) milling machine. Vickers hardness testing
Verma et al. 3

Figure 1. (a) Welded plate showing single V-groove joint and (b) transverse tensile specimen.

Table 1. Chemical composition of materials.

Material Si Cu Fe Zn Mg Ni Mn Cr Ti Sn Pb Al

5083 O 0.07 0.015 0.13 0.04 4.65 0.021 0.87 0.041 0.034 0.02 0.032 Rem.
6061 T6 0.79 0.19 0.0 0.07 0.98 0.03 0.17 0.045 0.03 0.025 0.024 Rem.
ER 4043 5.25 0.3 0.8 0.1 0.05 – 0.05 – 0.02 – – Rem.
ER 5356 0.03 0.01 0.15 0.01 4.83 – 0.14 0.11 0.09 – – Rem.

Table 2. Welding parameter.

Joint Groove Current Voltage Welding speed Filler wire Diameter of filler Argon flow
(A) (V) (mm/min) wire (mm) rate (L/min)

Butt joint Single V 210 23 200 ER 4043 and ER 5356 1.2 23

machine was used for measuring the hardness of the

weld metal, HAZ side I and HAZ side II (at the top,
middle and bottom sections) and base metals according
to procedures prescribed by the ASTM E92 standard.
The weld metal, HAZ (side I and side II) and base
metals are shown in schematic diagram in Figure 2.
Microstructural examination was carried out at weld
metal, HAZ side I and HAZ side II using an optical
microscope with polished surface using standard metal-
lographic techniques and etched with Keller’s reagent.
Microstructure of fractured surface in both samples Figure 2. Schematic diagram of welded plate.
was also examined. HAZ: heat-affected zone.

Results and discussion The specimen of both samples is shown in Figure 3.

Tensile strength and hardness
The tension tests were performed on FIE make
Universal Testing Machine (UTE-60), and it was
observed that the both samples, sample 1 (welded using
ER 4043 filler wire) and sample 2 (welded using ER
5356 filler wire), were fractured in weld metal region.
The tensile strength and the percentage of elongation
were evaluated based on the average of three values as
presented in Figure 4. The load–displacement diagrams
of a specimen of both samples are shown in the
Figure 5. The average tensile strength of samples 1 and
2 were 112 and 144 MPa, respectively. Thus, a 28.5%
increment was achieved when implementing ER 5356

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4 Proc IMechE Part B: J Engineering Manufacture

Figure 3. Photograph of specimen 1 and specimen 2.

(a) 160 144 MPa

Std. Dev. = 13.52
140 112 MPa
Std. Dev. = 4.63
Tensile strength (MPa)

120

100

80

60

40

20

0
Sample 1 Sample 2

(b) 4.5
4.16% Figure 5. Load–displacement diagram of (a) a specimen of
Std. Dev. = 0.93 sample 1 and (b) a specimen of sample 2.
4

3.5 respectively. The elongation was calculated from the

2.56% gauge length of this tensile specimen, and it contains
3
% elongaon

Std. Dev. = 0.47
2.5
2
1.5
1 comparison of ductility of samples. The use of ER 5356
0.5
0 A Vickers hardness test was performed at three dif-
Sample 1 Sample 2
Figure 4. Bar chart of (a) tensile strength (b) %elongation of
sample 1 and sample 2.
filler wire. An increase in tensile strength was also
observed in the literatures due to the strongly modified
microstructure. Generally, fine equiaxed grains tend to
improve mechanical properties of welded joint by
reducing solidification cracking. According to Hall–
Petch equation, s0 = si + kd(21/2) (where s0 is the
tensile stress, si is friction stress, k is a constant and d
is the mean grain diameter), tensile stress of metallic
materials varies inversely proportion to the grain size.
The comparative discussion is presented on the basis of
micrographs in section ‘Microstructure’.
The percentage of elongation was calculated from
load–displacement diagram, and an average value was
evaluated based on three values. The percentage of
elongation for samples 1 and 2 were 2.56% and 4.16%,
several parts of materials, including two different base
metals and two HAZs, weld metal. Each part contri-
butes its deformation to the total elongation value of
the specimen. Hence, the reported elongation is the
elongation of whole specimen, and it is used only for
filler wire in fabricating the joints increased the percent-
age of elongation of specimen by 62.5%.
ferent locations, at the top, middle and bottom, of weld
metals, HAZ side I and HAZ side II. The average hard-
ness values for sample 1 (welded using ER 4043 filler
wire) and sample 2 (welded using ER 5356 filler wire)
are shown in the Table 3. Figures 6 and 7 show the
hardness value of weld metal, HAZ side I and HAZ
side II at top, middle and bottom of samples 1 and 2,
respectively. A huge increment of 67.9% in hardness of
weld metal was observed when implementing ER5356
filler wire. Similarly, 11.3%, 7.2% and 6.2% incre-
ments were achieved in hardness of HAZ side I, base
metal 5083-O and base metal 6061-T6, respectively,
when using ER5356 filler wire. The refined microstruc-
ture is responsible for the increase in hardness.
Microstructure
Microstructure of joints was examined at weld metal
region and HAZ. From the micrographs, it is

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Verma et al. 5

Table 3. Hardness value (VHN) for sample 1 and sample 2.

Sample Locations Top Middle Bottom Average

Sample 1 Weld metal 38.0 55.7 57.9 50.5

HAZ side I 95.0 92.2 91.1 92.7
HAZ side II 74.1 64.9 76.7 71.8
Base metal (5083-O) – – – 92.6
Base metal (6061-T6) – – – 97.4
Sample 2 Weld metal 87.0 85.7 81.8 84.8
HAZ side I 104.3 104.0 101.3 103.2
HAZ side II 70.0 76.1 65.1 70.4
Base metal (5083-O) – – – 99.3
Base metal (6061-T6) – – – 103.5

VHN: Vickers hardness; HAZ: heat-affected zone.

micrograph of HAZ side I (Figure 8(a)), which consti-

Figure 6. Hardness variation of weld metal, HAZ side I and
HAZ side II for sample 1.
HAZ: heat-affected zone.
Figure 7. Hardness variation of weld metal, HAZ side I and
HAZ side II for sample 2.
HAZ: heat-affected zone.
understood that there is an appreciable difference in
grain size of weld metal regions and HAZ of both sam-
ples. Figure 8 shows the micrographs for sample 1. In
tutes base metal on right and weld metal on left. It
reveals that dendrites of solid solution are less equiaxed
at weld metal; however, the fusion of weld to base
metal (5083-O) is adequate. In micrograph of weld
metal (Figure 8(b)), as cast, annealed type weld show
interdendritic particles of eutectic silicon and the light
etching matrix of aluminium solid solution. The micro-
structure of HAZ side II (Figure 8(c)) includes base
metal on left and weld metal on right. The weld-base
metal transition show adequate fusion containing parti-
cles of Mg2Si (black) structure.
Figure 9(a) shows the micrographs of HAZ side I of
sample 2 constituting base metal, 5083-O (right) and
weld metal (left). In the micrograph, Al–Si eutectic is
present between the dendrites of weld bead and
AlMg2Si was present between the grains of the HAZ.
Fusion of weld to base metal is adequate, and there
was no any evidence of porosity. In the micrograph of
weld metal, shown in Figure 9(b), as cast, self-annealed
and crystalline structure shows particles of eutectic
solution in an aluminium matrix. Figure 9(c) shows the
micrographs of HAZ side II. The structure at edge of
the HAZ shows adequate fusion of weld to base metal.
Al–Si eutectic is present between the dendrites of the
weld bead. In micrograph, a localized porosity (large
black area) is evident; it is perhaps due to improper
cleaning of the sample.
The microstructure revealed response of the dissimi-
lar aluminium joint to filler metals. The revealed struc-
ture in Figure 9 shows a more dispersed precipitate of
Mg2Si intermetallic compound in Al-matrix. A well-
dispersed precipitate of the Mg2Si intermetallic com-
pound was responsible for the improved properties of
the sample 2. Fine equiaxed grains were observed for
sample 2. Fine equiaxed grains are capable to accom-
modate contraction strains more easily, that is, it is
more ductile than columnar grains, and it may result in
enhanced tensile strength of sample 2. Also, the grain
boundary area is much greater in fine-grained material
and therefore harmful low melting point segregates are
less concentrated at grain boundary, resulting in
enhanced mechanical properties.12 Hardness in the

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6 Proc IMechE Part B: J Engineering Manufacture
Figure 8. Optical micrographs of (a) HAZ side I, (b) weld metal region, (c) HAZ side II and (d) fractured surface of joint welded by
ER4043 filler metal.
HAZ: heat-affected zone.
fusion zone is the lowest due to the as-cast nature of
the microstructure, which is characterized by coarse
dendritic grains and interdendritic segregates. Hardness
is higher in sample 2 as compared to sample 1, and this
could be due to the refined microstructure and low seg-
regation of strengthening phases. Microstructures revel
less and dispersed porosity in sample 2. It is desirable
to limit porosity defects in aluminium weldments.
Columnar grains tend to produce an elongated poros-
ity, whereas the equiaxed grains tend to form a smaller
and more dispersed porosity.5 According to theory of
formation of gas porosity in aluminium alloys, the long
pores precipitate at a later stage of solidification, when
crystals/dendrites are growing throughout the melt and
are influenced by the hydrogen enrichment and the
shrinkage pressure in the columnar interdendritic area
during solidification. On the other hand, the small and
fissured pores precipitate at a very late stage of solidifi-
cation, the bubble growth is severely limited and the
shape is determined by the interdendritic space avail-
able. Therefore, the large amounts of equiaxed grains
solidified in the weldments tend to form the small and
dispersed porosity.18
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Conclusion
Based on this investigation, the following conclusion
can be made:
1. The welding of dissimilar aluminium alloy, 5083-O
and 6061-T6, is very difficult due to different ther-
mal conductivity. Excessive melting in alloy with
lower thermal conductivity and lack of fusion in
alloy with greater thermal conductivity are
observed. The selection of proper position of weld-
ing torch is very important parameter for the
strong weldments for dissimilar aluminium alloys.
In this work, good weldments are achieved by pla-
cing the torch above the edge of 6061-T6 alloy
plate.
2. Filler metal ER5356 is more appropriate for the
welding of alloy combination 5083-O and 6061-T6.
A 28.5% increment in tensile strength can be
achieved by ER5356 in comparison to ER4043. A
huge increment of 67.9% in weld metal hardness is
observed by ER5356 filler wire.
3. Similarly, 11.3%, 7.2% and 6.2% increment in
hardness can be achieved for 5083-O side HAZ,
Verma et al.
Figure 9. Optical micrographs of (a) HAZ side I, (b) weld metal region, (c) HAZ side II and (d) fractured surface of joint welded by
ER5356 filler metal.
HAZ: heat-affected zone.
5088-O base metal and 6061-T6 base metal, respec-
tively, by using ER5356 filler metal. However, no
much difference in hardness of 6061-T6 side HAZ
is observed.
4. The microstructure of HAZ side I zone, Weld
metal zone and HAZ side II zone made by ER5356
filler metal shows fine equiaxed grains, while
columnar grains are found in joints made by
ER4043 filler metal. Fine equiaxed grains are more
ductile than columnar grains, so it improves
mechanical properties, tensile strength, percentage
of elongation and hardness.
5. The microstructure of weld metal zone made by
ER5356 filler metal revels less and dispersed poros-
ity, while that made by ER4043 filler metal shows
elongated porosity.
Declaration of conflicting interests
The authors declare that there is no conflict of interest.
Funding
This research received no specific grant from any fund-
ing agency in the public, commercial or not-for-profit
sectors.
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7
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