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Thread: Aluminium filler wire

  1. #1
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    Aluminium filler wire

    Is the aluminum wire used in electrical service cable any good for filler rod when TIG welding aluminum?

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  2. #2
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    Re: Aluminium filler wire

    That would be fun to try. I recommend turning the power off on the service wire first.

  3. #3
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    Re: Aluminium filler wire

    From what I've read, aluminum electrical service wire is close to pure aluminum or a 1XXX alloy. Most aluminum TIG fillers are 4XXX or 5XXX containing silicon or magnesium as principal additives. For reference: https://www.clintonaluminum.com/the-...s-for-welding/

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  5. #4
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    Re: Aluminium filler wire

    Give it a try then beat on it with a hammer. Should have a lot of strength and bend your base metal some or a lot before the weld breaks. If itís strong it wonít break at the weld

  6. #5
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    Re: Aluminium filler wire

    I have used a bunch of the electrical wire as filler material for my scrap metal art projects. It works fine and seems to hold up pretty well. It all depends on what you are using it for.
    Millermatic 252 MIG
    Miller Dynasty 200DX TIG
    Miller Spectrum 625 Plasma
    Altas 12x36 Metal Lathe
    Bridgeport Milling Machine
    www.psacustomcreations.com

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  8. #6
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    Re: Aluminium filler wire

    Thanks everyone for the information!

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  9. #7
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    Re: Aluminium filler wire

    The guy on youtube's "Project Farm" has done some tests and comparisons of aluminum welding rods that can "weld" aluminum with a propane or MAPP torch. I wonder if one could use the electrical wire (heavy gauge) like those rods.

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  11. #8
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    Re: Aluminium filler wire

    Quote Originally Posted by shortfuse View Post
    The guy on youtube's "Project Farm" has done some tests and comparisons of aluminum welding rods that can "weld" aluminum with a propane or MAPP torch. I wonder if one could use the electrical wire (heavy gauge) like those rods.
    I don't think it would bond very good... I've done a good amount of repair work with the low temp aluminum 'welding' rods and I believe it is the other metals in the mix that make it braze(for lack of a better word) onto the base metal...... I think Now... with that said I can also say I have never tried to use(for welding) some pure aluminum out of a conductor.... but I have melted it with a torch

  12. #9
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    Re: Aluminium filler wire

    I went back and looked at Project Farm's aluminum electrode video...I think those electrodes do indeed have some allow metals in them. Thanks for the head's up.

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  14. #10
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    Re: Aluminium filler wire

    Quote Originally Posted by shortfuse View Post
    I went back and looked at Project Farm's aluminum electrode video...I think those electrodes do indeed have some allow metals in them. Thanks for the head's up.
    Oh they actually have quite an assortment of metals in them

    Can't remember the details but remember talking at length to a guy from Perth working for the original manufacturer(forget the name) of the low temp aluminum welding sticks.. he was telling us how they have one of the tallest full vacuum chambers in the world that these get made in and how their chamber got inspected every single day head to toe!!! and a bunch of other details about the different alloys in the mix..I think the said there were at least a dozen including sterling silver... last ones I got from HF and I didn't even notice if they were from china land or not???

  15. #11
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    Re: Aluminium filler wire

    I think the Blue Demon sticks (regular and aluminum) are all made in USA.

  16. #12
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    Re: Aluminium filler wire

    Quote Originally Posted by ronsii View Post
    I don't think it would bond very good... I've done a good amount of repair work with the low temp aluminum 'welding' rods and I believe it is the other metals in the mix that make it braze(for lack of a better word) onto the base metal...... I think Now... with that said I can also say I have never tried to use(for welding) some pure aluminum out of a conductor.... but I have melted it with a torch
    If what Dennis says about aluminum electrical wire is correct it might work. 1XXX series aluminum has been used forever for welding with an oxy/hydrogen torch.

    Artsy stuff or practice Iíd try it if thatís all you have, but wouldnít attempt it on anything that actually required a strong weld. Iíve only ever seen it used with thin aluminum, under 1/8Ē. Filler metal isnít that expensive.

    Adding: It also depends on what the base metal is, you donít want to use a 1XXX series for filler on say a 5XXX or 6XXX base metal. Iíd just buy some actual TIG rods and be done with it.
    Last edited by Mike_L; 12-19-2020 at 12:01 AM.

  17. #13
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    Re: Aluminium filler wire

    Quote Originally Posted by billwood437 View Post
    Is the aluminum wire used in electrical service cable any good for filler rod when TIG welding aluminum?

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    So, aluminum electrical wire is made to carry electrical current without arcing, and you want to use it while arcing? Geeesh.

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  19. #14
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    Re: Aluminium filler wire

    Quote Originally Posted by Weldordie View Post
    So, aluminum electrical wire is made to carry electrical current without arcing, and you want to use it while arcing? Geeesh.
    But.... it's actually pretty poor at doing that... hence why they quit using it in manufactured houses around here some 30-40 years ago turns out it was pretty good at arcing

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