Find the right filler metal for your weld. Select base materials, joint type, and welding process to get filler rod, shielding gas, and technique recommendations for TIG, MIG, and stick welding.
Last updated April 2026
5356 for better strength, 4043 for crack resistance and color match when anodizing.
| Filler | Type | Base Materials | Process | Shielding Gas | Notes |
|---|---|---|---|---|---|
| ER4043 | Aluminum | 6061, 3003, 356 castings | TIG / MIG | 100% Argon | Most common Al filler. Good fluidity, crack resistant. Slightly darker anodize color. |
| ER5356 | Aluminum | 5052, 5083, 6061, dissimilar Al | TIG / MIG | 100% Argon | Higher strength than 4043. Better color match for anodizing. Not for service > 150F (Mg migration). |
| ER1100 | Aluminum | 1100, 3003 | TIG / MIG | 100% Argon | Pure aluminum filler. Best color match, lowest strength. |
| ER70S-2 | Carbon Steel | Mild steel, thin wall 4130 | TIG | 100% Argon | Triple-deoxidized. Excellent for TIG on dirty or rusty material. |
| ER70S-6 | Carbon Steel | A36, 1018, mild steel | TIG / MIG | TIG: 100% Ar / MIG: 75/25 Ar/CO2 | Most common carbon steel wire. High silicon and manganese for deoxidation. |
| E7018 | Carbon Steel | A36, structural steel | Stick (SMAW) | Self-shielded | Low-hydrogen electrode. Standard structural rod. Must be kept dry (rod oven). |
| E6013 | Carbon Steel | Mild steel, sheet metal | Stick (SMAW) | Self-shielded | Easy arc start, AC or DC. Good for thin material and general purpose. |
| ER80S-D2 | Alloy Steel | 4130, 4140 chromoly | TIG / MIG | TIG: 100% Ar / MIG: 75/25 Ar/CO2 | Chrome-moly filler. PWHT typically required above 0.120" wall thickness. |
| E8018-B2 | Alloy Steel | 4130, 4140 chromoly | Stick (SMAW) | Self-shielded | 1.25Cr-0.5Mo electrode. PWHT required. |
| ER308L | Stainless Steel | 304, 304L stainless | TIG / MIG | TIG: 100% Ar / MIG: Tri-mix | Standard 304 filler. L = low carbon to prevent sensitization. |
| E308L-16 | Stainless Steel | 304 stainless | Stick (SMAW) | Self-shielded | -16 titania coating, AC or DCEP. -15 basic coating, DCEP only. |
| ER316L | Stainless Steel | 316, 316L stainless | TIG / MIG | TIG: 100% Ar / MIG: Tri-mix | Contains Mo for improved corrosion resistance. Required for 316 base. |
| ER309L | Stainless Steel | Dissimilar: 304/316, carbon steel to stainless | TIG / MIG / Stick | Varies by process | The universal dissimilar stainless filler. Bridges composition gaps. |
For TIG welding 6061 aluminum, use ER4043 filler for general-purpose work (good fluidity, less crack-sensitive, bright finish) or ER5356 when higher shear strength and better color match after anodizing are needed. ER4043 is the default choice for most 6061 applications. Use pure argon shielding gas at 15-25 CFH for all aluminum TIG welding.
7075 aluminum is generally considered unweldable by fusion methods due to its high zinc content, which causes severe hot cracking in the heat-affected zone. It cannot be reliably TIG or MIG welded for structural applications. Alternatives include friction stir welding, mechanical fastening, or redesigning with weldable alloys like 6061 or 5083 for welded joints.