Aluminum welding isn’t a one-size-fits-all process. That’s because not all aluminum is the same — there are many different alloys, each with unique characteristics. Choosing the right aluminum alloy for your project is critical to achieving strong, durable welds. At Pegasus Mobile Welding, our certified welders understand the strengths and weaknesses of each aluminum type, allowing us to choose the best approach whether we’re working on a truck body, a structural beam, or a custom aluminum build.
Understanding the Different Series of Aluminum Alloys
Aluminum alloys are divided into series based on their primary alloying elements. Here’s a quick overview:
- 1XXX series – Commercially pure aluminum. Excellent corrosion resistance and conductivity but low strength.
- 2XXX series – Copper alloys. Strong, but difficult to weld.
- 3XXX series – Manganese-based. Good formability but limited strength.
- 4XXX series – Silicon-based. Often used as filler metals.
- 5XXX series – Magnesium-based. Great weldability and corrosion resistance.
- 6XXX series – Magnesium and silicon. Excellent all-purpose alloy group.
- 7XXX series – Zinc-based. High strength but very hard to weld.
The most commonly welded alloys in mobile applications are from the 5XXX and 6XXX series.
Why 5XXX Series Aluminum Is the Go-To Choice for Welders
The 5XXX series, particularly 5052 and 5083, offers excellent strength and corrosion resistance, making it ideal for mobile trailer repair, marine fabrication, and structural projects. These alloys are non-heat-treatable and weld well using both TIG and MIG processes. At Pegasus, we typically use ER5356 filler wire for added durability and corrosion resistance when MIG welding 5XXX aluminum.
Need help with structural aluminum repairs? Our Aluminum Welding team is ready to assist with high-quality results wherever you need us.
Working with 6XXX Series Aluminum: 6061 and 6063
6061 and 6063 alloys are heat-treatable and commonly used in frames, structural components, and piping. They offer a great mix of formability and strength but are slightly more prone to cracking than 5XXX series. We typically use ER4043 filler wire for smoother welds or ER5356 for higher strength needs. For finer, cleaner welds, we often turn to Aluminum TIG Welding when working with 6XXX series alloys.
Why 2XXX and 7XXX Series Alloys Are Difficult to Weld
The 2XXX and 7XXX series aluminum alloys offer incredible strength, making them common in aerospace applications. However, they are highly prone to hot cracking, especially when welded without special procedures. These alloys often require preheating, post-weld heat treatment, and highly specific filler metals. If your project involves these materials, trust only a certified mobile welder near me to ensure long-term success.
Choosing the Right Filler Wire for Each Aluminum Alloy
Welding aluminum is not just about the base metal—it’s also about the filler metal. Here’s a quick breakdown of common fillers:
- ER4043: Ideal for 6XXX series. Smooth welds and good crack resistance.
- ER5356: Strong, corrosion-resistant. Preferred for 5XXX series.
- ER5554: High-strength marine or automotive work.
At Pegasus Mobile Welding, we always check material compatibility before we weld, selecting the best filler for the task. For reliable Aluminum MIG Welding, we come fully prepared to handle any alloy challenge onsite.
Why Alloy Knowledge Matters in Mobile Aluminum Welding
Welding aluminum outdoors or in the field adds extra complexity. Aluminum is sensitive to temperature shifts, wind, and contamination. Pegasus Mobile Welding technicians use portable power, argon shielding gas, and alloy-specific tools to make sure the weld is clean and strong—no matter where we’re working. Whether it’s a quick repair or a full structural weld, our experience with different aluminum alloys means you get dependable results every time.
If you’re planning a project and need expert welders who understand aluminum from the inside out, contact Pegasus Mobile Welding. We’ll bring the shop to you—with all the knowledge and precision you need.