Aluminum ER5654
ASTM AWS A5.10 ER5654 · EN S Al 5654A
ER5654 is a high-purity Al-Mg filler to AWS A5.10 ER5654 (S Al 5654A) with controlled trace elements for welding 5652/5654 hydrogen peroxide and high-purity chemical storage tanks.
Reference datasheet — ER5654 is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the AW condition
ER5654 tempers and conditions
ER5654 is supplied in 3 conditions, soft to hard. AW is the default FabDigit quotes; the values on this page are for it.
Compare all 3 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
AWDefault As-welded deposit | Default condition for filler metals: properties of the as-deposited all-weld metal with no post-weld heat treatment. | 115 | 240 | 20 | 58 HB | 33 % IACS |
Annealed | Pick for TIG/GTAW cut lengths where soft, straight, easily hand-fed rod is wanted. | 115 | 240 | 25 | 58 HB | 33 % IACS |
cold-drawn spooled MIG wire | Pick for spooled GMAW wire: cold-drawn temper gives the column strength and stiffness needed for trouble-free feeding of soft Al-Mg wire. | 255 | 320 | 8 | 85 HB | 32 % IACS |
What is ER5654?
ER5654 is a high-purity Al-Mg filler to AWS A5.10 ER5654 (S Al 5654A) with controlled trace elements for welding 5652/5654 hydrogen peroxide and high-purity chemical storage tanks. Supplied as cold-drawn GMAW spool wire and annealed GTAW cut lengths, deposits run about 240 MPa tensile, 115 MPa yield, 20 % elongation, 58 HB and 127 W/m·K, with the best corrosion rating in this filler group. Service is limited to roughly 65 °C, and iron- or copper-bearing tooling and consumables must be kept away from the joint; ER5254 is the nearest substitute. ER5654 has a density of 2.66 g/cm³ (0.0961 lb/in³), lighter than 84% of aluminum grades. It melts at 593°C (1,099 °F). ER5654 has a yield strength of 115 MPa (16.7 ksi) and a tensile strength of 240 MPa (34.8 ksi) — weaker than 79% of aluminum grades. Elongation at break is 20% and the elastic modulus is 70.3 GPa (10.2 Msi).
What is ER5654 used for?
- hydrogen peroxide tanks
- high-purity chemical storage
- semiconductor chemical delivery systems
Advantages
- Good corrosion resistance — 80/100, better than 97% of aluminum grades
- Readily welded — 92/100, better than 95% of aluminum grades
- Ductile — tolerates forming and impact — 20%, better than 89% of aluminum grades
- Forms and bends easily — 80/100, better than 89% of aluminum grades
Limitations
- Limited service temperature — 65°C (149 °F), worse than 97% of aluminum grades
- Low strength — 115 MPa (16.7 ksi), worse than 79% of aluminum grades
ER5654 properties
Typical room-temperature values for ER5654-AW; bars are the position among aluminum grades.
Physical3
ER5654 has a density of 2.66 g/cm³ (0.0961 lb/in³), lighter than 84% of aluminum grades. It melts at 593°C (1,099 °F).
Mechanical10
ER5654 has a yield strength of 115 MPa (16.7 ksi) and a tensile strength of 240 MPa (34.8 ksi) — weaker than 79% of aluminum grades. Elongation at break is 20% and the elastic modulus is 70.3 GPa (10.2 Msi).
Thermal6
ER5654 is rated for continuous service to 65°C (149 °F). It conducts heat at 127 W/m·K (73.4 BTU/hr·ft·°F), worse than 69% of aluminum grades. Thermal expansion is 23.9 µm/m·K (13.3 µin/in·°F).
Electrical3
ER5654 conducts electricity at 33 % IACS, worse than 57% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is very good (80/100), better than 97% of aluminum grades.
Sustainability4
Producing a kilogram of ER5654 takes about 200 MJ of energy and emits 12.5 kg of CO₂ — less than 60% of aluminum grades. Typical recycled content is 5%.
Manufacturability7
ER5654's machinability is fair (45/100, worse than 72% of aluminum grades); weldability excellent (92/100); formability very good (80/100).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the aluminum family
Yield strength against density for every aluminum grade FabDigit runs. ER5654 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with ER5654
Is ER5654 easy to machine?
Weld deposit is soft and gummy — use sharp polished high-rake carbide, high surface speed and generous lubrication to avoid built-up edge; dressing of peroxide-service welds should use clean, iron-free tooling.
Can ER5654 be welded?
Runs as GMAW spool wire or GTAW rod on 5652/5654/5154 (and other Mg-bearing 5000 series) with AC-TIG or spray-transfer pulsed MIG; keep interpass temperature low, use dedicated stainless brushes and Fe/Cu-free consumable handling to preserve purity, and avoid on Cu-bearing 2000-series alloys.
Can ER5654 be formed, bent or molded?
Supplied as cold-drawn spool wire or annealed cut lengths; straightening and re-coiling are routine, but avoid drawing lubricant residues that would contaminate high-purity joints.
ER5654 chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| Mg | 3.1 – 3.9 | 3.5 |
| Cr | 0.15 – 0.35 | 0.25 |
| Tigrain refiner | 0.05 – 0.15 | 0.1 |
| Si+Fecombined limit | ≤ 0.45 | |
| Cu | ≤ 0.05 | |
| Mnvery tight limit for peroxide service | ≤ 0.01 | |
| Zn | ≤ 0.2 | |
| Belimit applies where specified/older editions | ≤ 3×10⁻⁴ | |
| Others (each)0.15 total | ≤ 0.05 | |
| Al | balance |
What surface finishes work on ER5654?
Normally left bare and passivated/cleaned (nitric-acid or citric cleaning) for peroxide tanks; anodizes clear-to-grey if a decorative finish is required, and welds should be pickled rather than painted in chemical service.
Surface treatments FabDigit runs on aluminum parts — pick them in the quote configurator or call them out on the drawing. Each links to its datasheet in the surface-finish library (thickness, specs, call-out, material verdicts).
Organic Coating
Equivalent designations
Standards and trade names that resolve to Aluminum ER5654 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- ASTM
- AWS A5.10 ER5654
- EN / DIN / Werkstoff-Nr.
- S Al 5654A
- Other
- 5654
How much does ER5654 cost?
ER5654 is a high-cost aluminum ($$$$), pricier than about 78% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
ER5654 — frequently asked
What is ER5654 used for?
ER5654 is typically used for hydrogen peroxide tanks, high-purity chemical storage and semiconductor chemical delivery systems. In short: highest-purity Al-Mg filler; for peroxide and ultrapure tanks; best corrosion rating in family.
What is the yield strength of ER5654?
ER5654 has a typical yield strength of 115 MPa (16.7 ksi) and a tensile strength of 240 MPa (34.8 ksi) — weaker than 79% of aluminum grades. Strength varies by condition: see the 3 listed tempers.
Is ER5654 easy to machine?
Reasonably — machinability is rated fair (45/100, worse than 72% of aluminum grades). Weld deposit is soft and gummy — use sharp polished high-rake carbide, high surface speed and generous lubrication to avoid built-up edge; dressing of peroxide-service welds should use clean, iron-free tooling.
Can ER5654 be welded?
Yes — weldability is rated excellent (92/100). Runs as GMAW spool wire or GTAW rod on 5652/5654/5154 (and other Mg-bearing 5000 series) with AC-TIG or spray-transfer pulsed MIG; keep interpass temperature low, use dedicated stainless brushes and Fe/Cu-free consumable handling to preserve purity, and avoid on Cu-bearing 2000-series alloys.
What surface finishes work on ER5654?
Normally left bare and passivated/cleaned (nitric-acid or citric cleaning) for peroxide tanks; anodizes clear-to-grey if a decorative finish is required, and welds should be pickled rather than painted in chemical service.
Can ER5654 be formed, bent or molded?
Supplied as cold-drawn spool wire or annealed cut lengths; straightening and re-coiling are routine, but avoid drawing lubricant residues that would contaminate high-purity joints.
What is the maximum service temperature of ER5654?
ER5654 is rated for continuous use to about 65°C (149 °F). Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between ER5654-AW and ER5654-H1X?
AW is the default condition — default condition for filler metals: properties of the as-deposited all-weld metal with no post-weld heat treatment. H1X: pick for spooled GMAW wire: cold-drawn temper gives the column strength and stiffness needed for trouble-free feeding of soft Al-Mg wire. Yield strength is 115 MPa in AW versus 255 MPa in H1X.
How much does ER5654 cost?
ER5654 is a high-cost aluminum ($$$$), pricier than about 78% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- AWS A5.10/A5.10M — Bare Aluminum and Aluminum-Alloy Welding Electrodes and Rods — AWS (2021)
- ISO 18273 — Welding consumables, wire electrodes/rods for aluminium and aluminium alloys (S Al 5654A) — ISO (2015)
- Teal Sheets — International Alloy Designations and Chemical Composition Limits for Wrought Aluminum — The Aluminum Association (2018)
- ASM Handbook Vol. 2 — Properties and Selection: Nonferrous Alloys (5154/5254/5654) — ASM International (1990)
- ASM Handbook Vol. 13B — Corrosion: Materials (aluminium alloys) — ASM International (2005)
- Aluminium filler metal selection and handling guides — ESAB / Lincoln Electric / Alcoa (2022)
- (ER5xxx) (2026)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.