Aluminum ER5654-O (Annealed)
Temper
ASTM AWS A5.10 ER5654 · EN S Al 5654A
Pick for TIG/GTAW cut lengths where soft, straight, easily hand-fed rod is wanted.
Values for the O condition
Other ER5654 tempers and conditions
ER5654 is listed in 3 conditions; see the grade overview at ER5654.
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 |
OThis page 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-O?
ER5654-O is ER5654 in the O temper — pick for TIG/GTAW cut lengths where soft, straight, easily hand-fed rod is wanted. ER5654-O 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 25% and the elastic modulus is 70.3 GPa (10.2 Msi). ER5654-O 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). AW is the default condition FabDigit quotes; O is available on request or by drawing note.
Advantages
- Good corrosion resistance — 82/100, better than 99% of aluminum grades
- Readily welded — 92/100, better than 95% of aluminum grades
- Ductile — tolerates forming and impact — 25%, better than 94% of aluminum grades
- Forms and bends easily — 85/100, better than 91% of aluminum grades
Limitations
- Limited service temperature — 65°C (149 °F), worse than 97% of aluminum grades
- Difficult to machine — 40/100, worse than 81% of aluminum grades
- Low strength — 115 MPa (16.7 ksi), worse than 79% of aluminum grades
ER5654-O properties
Typical room-temperature values for ER5654-O; 18 are specific to this condition. Other listed values are ER5654 reference data and may not represent this condition. Bars are the position among aluminum grades.
Physical3
ER5654-O 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-O 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 25% and the elastic modulus is 70.3 GPa (10.2 Msi).
Thermal6
ER5654-O 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-O conducts electricity at 33 % IACS, worse than 57% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is very good (82/100), better than 99% of aluminum grades.
Sustainability4
Producing a kilogram of ER5654-O 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-O's machinability is fair (40/100, worse than 81% of aluminum grades); weldability excellent (92/100); formability excellent (85/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with ER5654-O
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.
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.
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 | — |
ER5654-O — frequently asked
What is ER5654-O used for?
ER5654-O 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-O?
ER5654-O 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-O easy to machine?
Not especially — machinability is rated fair (40/100, worse than 81% 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-O 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-O?
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-O 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-O?
ER5654-O 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.
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. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.