Aluminum 5005 vs 5083: A Comprehensive Comparison

When it comes to choosing the right aluminum alloy for your project, the options can be overwhelming. Two popular choices, Aluminum 5005 and 5083, each bring unique properties to the table. But what’s the difference between them, and which one is better suited for your needs? In this comprehensive comparison, we’ll delve into the chemical compositions, corrosion resistance, strength, formability, machinability, weldability, cost, and sustainability of these two alloys. Whether you’re looking to understand their suitability for marine or aerospace applications, or simply need to know which alloy will perform best under specific conditions, this article has you covered. Ready to discover which aluminum alloy will take your project to the next level? Let’s dive in.

Composition Comparison

Aluminum 5005 is an alloy mainly made of aluminum, with magnesium as its key component. Other elements present in Aluminum 5005 include up to 0.2% manganese, up to 0.7% iron, and up to 0.3% silicon. These additional elements help to improve the alloy’s mechanical properties and its ability to be anodized, making it suitable for decorative and architectural applications.

Aluminum 5083 has a much higher magnesium content, ranging from 4.0% to 4.9%, which significantly enhances its strength and corrosion resistance, especially in marine environments. The alloy also contains 0.4% to 1.0% manganese and 0.05% to 0.25% chromium, which improve its mechanical properties and corrosion resistance. Additionally, it includes up to 0.4% iron, up to 0.4% silicon, up to 0.1% copper, and up to 0.25% zinc.

The higher levels of magnesium, manganese, and chromium in 5083 give it superior strength and corrosion resistance, making it more suitable for demanding applications compared to 5005.

Corrosion Resistance in Different Environments

Overview of Corrosion Resistance Properties

Corrosion resistance is a critical factor when selecting aluminum alloys for various applications, particularly those exposed to harsh environmental conditions. Corrosion resistance refers to the ability of a material to withstand damage caused by oxidation or other chemical reactions over time. Aluminum alloys like 5005 and 5083 are known for their excellent corrosion resistance, although their performance can vary depending on the environment.

Performance of Aluminum 5005 in Various Environments

Aluminum 5005 is an alloy that offers moderate corrosion resistance, making it suitable for general applications. Its primary alloying element is magnesium, which contributes to its ability to form a protective oxide layer, helping prevent further oxidation and corrosion, especially in atmospheric conditions. In environments with minimal exposure to aggressive agents, such as urban or rural atmospheres, Aluminum 5005 performs well. However, in marine environments, where exposure to saltwater and high humidity is common, its corrosion resistance is less robust. Chloride ions in seawater can break through the protective layer, causing pitting and crevice corrosion. Therefore, while it can be used in marine applications, it may require additional protective measures, such as coatings or anodization, to enhance its durability. In industrial settings, where exposure to pollutants and chemicals may occur, Aluminum 5005’s performance is moderate. It can resist mild chemical exposure but may not be the best choice for environments with frequent contact with harsh chemicals or acidic substances.

Performance of Aluminum 5083 in Various Environments

Aluminum 5083 is renowned for its superior corrosion resistance, particularly in demanding environments. Its higher magnesium content, along with the presence of manganese and chromium, significantly enhances its ability to withstand corrosion. Aluminum 5083 is exceptionally well-suited for marine environments. Its high magnesium content allows it to form a thicker and more stable oxide layer, providing excellent protection against seawater corrosion. This makes it a preferred choice for applications such as shipbuilding, where prolonged exposure to saltwater is a concern. In environments where the material is exposed to harsh chemicals, Aluminum 5083’s corrosion resistance is also superior. The alloy’s composition allows it to maintain its integrity even when in contact with aggressive substances, making it suitable for chemical processing equipment and storage tanks. In typical atmospheric conditions, Aluminum 5083 performs just as well as 5005. However, its enhanced protective properties make it a better option for locations with higher pollution levels or more aggressive environmental factors.

Comparative Analysis of Corrosion Resistance

When comparing the corrosion resistance of Aluminum 5005 and 5083, several key points emerge:

• General Corrosion Resistance: Both alloys offer good corrosion resistance in general atmospheric conditions. However, Aluminum 5083 provides a higher level of protection due to its enhanced alloying elements.
• Marine Environments: Aluminum 5083 is distinctly superior in marine environments, offering exceptional resistance to saltwater corrosion. Aluminum 5005, while usable, may require additional protection.
• Chemical Exposure: For environments with exposure to harsh chemicals, Aluminum 5083 is the better choice, thanks to its robust resistance to aggressive substances.
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  Strength and Durability

Tensile Strength of Aluminum 5005

Aluminum 5005 is known for its moderate strength, with a tensile strength typically around 180 MPa in the H16 temper. Its yield strength is approximately 160 MPa in the same temper. These values indicate that while 5005 is not among the highest strength aluminum alloys, it provides sufficient strength for applications where high strength is not the primary requirement.

Tensile Strength of Aluminum 5083

Aluminum 5083 is recognized for its high strength, boasting a tensile strength of about 330 MPa in the H32 temper. Its yield strength is around 240 MPa in the same temper. The significantly higher tensile and yield strengths make 5083 a robust option for applications demanding high strength and durability.

Comparative Analysis of Strength and Durability

Strength Comparison

When comparing the strength of Aluminum 5005 and 5083, several points stand out. Aluminum 5083 has nearly double the tensile strength and significantly higher yield strength than Aluminum 5005, making it more suitable for structural applications and environments with high mechanical loads. While 5005 is adequate for many applications, its lower strength makes it less suitable for heavy-duty applications compared to 5083.

Durability Analysis

The durability of an alloy depends on its resistance to mechanical wear and environmental factors. Aluminum 5005, with its moderate strength, offers sufficient durability for many standard applications but may not be ideal for environments with high mechanical stress or harsh conditions. The higher strength and better fatigue resistance of Aluminum 5083 contribute to its superior durability. It can withstand more demanding conditions, including marine and industrial environments where mechanical and environmental stresses are higher.

In essence, while both Aluminum 5005 and 5083 provide valuable performance characteristics, 5083 stands out for applications that require higher strength and enhanced durability.

Formability and Machinability

Formability and Machinability

Formability and machinability are crucial properties to consider when selecting aluminum alloys for various applications. Understanding these properties helps in determining the suitability of an alloy for specific manufacturing processes and end-use requirements.

Formability

Formability refers to the ability of a material to undergo plastic deformation without being damaged. It is a key consideration in processes such as bending, stretching, and drawing.

• Formability of Aluminum 5005: Aluminum 5005 is highly formable, meaning it can be easily shaped and bent without cracking. This alloy can be molded into complex shapes and offers high ductility, making it ideal for applications requiring significant deformation. Its higher elongation at break and lower yield strength compared to Aluminum 5083 facilitate easier forming operations.
• Formability of Aluminum 5083: Aluminum 5083, while possessing high strength, has lower formability compared to 5005. Its higher yield strength means it needs more force to deform and is more likely to crack during extensive forming. Therefore, it is less suitable for applications where intricate shapes are needed.

Machinability

Machinability describes how easily a material can be cut, drilled, or machined using tools. It affects the efficiency and quality of machining operations.

• Machinability of Aluminum 5005: Aluminum 5005 is relatively easy to machine due to its moderate strength and high ductility, which reduce tool wear and allow for smooth cutting operations. This makes it a favorable choice for applications requiring extensive machining.
• Machinability of Aluminum 5083: Aluminum 5083, with its higher strength, presents more challenges in machining compared to 5005. It requires sharper tools and higher cutting forces. Despite these challenges, it still maintains good machinability for a high-strength alloy, making it suitable for applications where both strength and machining are required.

When comparing the formability and machinability of Aluminum 5005 and 5083, several key points stand out:

• Formability: Aluminum 5005 excels with its superior formability, making it more suitable for applications that require intricate shapes and high ductility. In contrast, Aluminum 5083, with its higher strength, is less ideal for extensive forming but excels in applications where strength is paramount.
• Machinability: Aluminum 5005 offers easier machining due to its lower strength and higher ductility, leading to smoother operations and less tool wear. Aluminum 5083, while machinable, requires more precise tooling and higher forces, which can increase machining complexity and cost.

These differences highlight the importance of selecting the right alloy based on the specific requirements of the application, balancing the need for formability and machinability with the desired strength and durability.

Weldability Comparison

Explanation of Weldability

Weldability refers to the ability of a material to be welded under specific conditions, resulting in a weld joint that has properties close to those of the base material. Factors influencing weldability include alloy composition, thermal properties, mechanical properties, and the presence of impurities.

Weldability of Aluminum 5005

Aluminum 5005 is widely recognized for its good weldability. It can be welded using common methods such as Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW). The alloy’s moderate strength and good ductility contribute to its ease of welding.

Filler Material Compatibility

For welding Aluminum 5005, filler materials such as 4043 or 5356 are often used, and the choice of filler material affects the final properties of the weld. 4043 is preferred for its good flow characteristics and lower melting point, which helps reduce the risk of cracking. Conversely, 5356 is used when higher strength is required in the weld joint.

Welding Considerations

During the welding of Aluminum 5005, it is important to control heat input to prevent warping and ensure adequate penetration. Pre-weld cleaning is crucial to remove any oxide layer and contaminants that can affect the quality of the weld.

Weldability of Aluminum 5083

Aluminum 5083 is highly weldable, especially in marine and industrial settings. Its high strength and excellent corrosion resistance make it a preferred choice for welding.

Filler Material Compatibility

The preferred filler materials for welding Aluminum 5083 are from the 5XXX series, such as 5356 and 5183. These fillers are chosen to match the high magnesium content of the base alloy, ensuring strong and ductile welds. The use of 5XXX series fillers helps maintain the alloy’s mechanical properties and corrosion resistance.

Welding Considerations

Welding Aluminum 5083 requires careful control of parameters to manage its higher strength and potential for stress-corrosion cracking. It is essential to use appropriate welding techniques and post-weld treatments to relieve residual stresses and enhance the weld’s integrity.

Comparative Analysis of Weldability

General Weldability

Both Aluminum 5005 and 5083 are weldable, but 5083 offers superior weldability due to its alloy composition and mechanical properties. The higher magnesium content in 5083 boosts its strength and improves the weld joint’s performance.

Filler Material Selection

While both alloys can be welded using fillers like 5356, the choice of filler for 5005 may include 4043 for better flow and reduced cracking risk. For 5083, 5XXX series fillers are essential to maintain the alloy’s properties, particularly in demanding applications.

Practical Applications

Aluminum 5083 is preferred for applications requiring high strength and excellent corrosion resistance, such as marine environments and heavy-duty structures. Aluminum 5005 is suitable for applications where moderate strength and good formability are sufficient, such as architectural elements and general construction.

Cost and Sustainability Factors

Evaluating the cost factors of aluminum alloys 5005 and 5083 requires considering both production costs and market prices.

Production costs for aluminum alloys are influenced by the raw materials used, manufacturing processes, and market demand. Aluminum 5083 generally incurs higher production costs compared to 5005 due to its higher magnesium content, which ranges between 4.0% and 4.9%. Magnesium prices can fluctuate, impacting the
Sustainability is crucial in choosing materials, focusing on their environmental impact and energy use.

Both Aluminum 5005 and 5083 are recyclable, which greatly reduces their environmental impact compared to producing new aluminum. Recycling aluminum requires about 95% less energy than primary production. This recyclability makes both alloys sustainable options when recycled properly, minimizing waste and conserving resources.

The production of aluminum alloys demands significant energy, but using recycled aluminum can greatly reduce this requirement. Both 5005 and 5083 benefit from similar thermal diffusivity properties, though 5083 has slightly higher thermal shock resistance. This difference can influence heating and cooling processes during manufacturing, potentially offering minor energy savings for 5083 in specific scenarios.

Knowing how Aluminum 5005 and 5083 are used and their lifecycle helps determine their cost-effectiveness and sustainability in real-world applications.

Aluminum 5005 is primarily used in decorative and aesthetic applications due to its corrosion resistance and ease of forming. Common uses include building exterior materials, cookware, and household appliances. Its lower strength limits its suitability for high-load applications, but it remains a cost-effective option for projects where mechanical strength is not critical.

Aluminum 5083, with its high strength, corrosion resistance, and weldability, is ideal for structural components in marine environments, pressure vessels, and automotive parts. Its ability to endure harsh conditions extends its lifecycle, making it a durable and sustainable choice for demanding applications. The initial higher production costs of 5083 can be offset by its longer lifespan and reliability in challenging environments.

When comparing Aluminum 5005 and 5083, several key points emerge:

• Cost-Effectiveness: Aluminum 5005 is more cost-effective for applications where high strength is not required. Its lower production costs and market prices make it suitable for decorative purposes and general uses.
• Sustainability: Both alloys offer significant sustainability benefits through recyclability, reducing their environmental impact. Aluminum 5083, despite higher production costs, provides long-term sustainability due to its extended lifecycle in demanding applications.
• Energy Efficiency: The use of recycled aluminum significantly enhances the energy efficiency of both alloys. The slightly higher thermal shock resistance of 5083 may offer marginal energy savings during manufacturing processes.

These factors highlight the importance of selecting the appropriate alloy based on specific project requirements, balancing cost and sustainability considerations to achieve the best performance and value.

Applications in Marine Industries

Selecting the right materials for marine applications is vital due to the harsh conditions, including saltwater exposure, humidity, and mechanical stresses.

Suitability of Aluminum 5005 for Marine Applications

Aluminum 5005 offers moderate corrosion resistance, making it suitable for less demanding marine environments, and it performs adequately with minimal exposure to aggressive agents. Typical uses of Aluminum 5005 in marine industries include:

• Decks and Superstructures: Aluminum 5005 can be used for non-structural components such as decks and superstructures where high strength is not critical.
• Interior Components: Due to its good formability and aesthetic appeal, Aluminum 5005 is often used for interior components and fixtures on marine vessels.

However, in environments with constant exposure to seawater, Aluminum 5005 may require additional protective measures like coatings or anodization to enhance its durability.

Suitability of Aluminum 5083 for Marine Applications

Aluminum 5083 is highly suitable for marine applications because it offers superior corrosion resistance and high strength, designed to withstand challenging marine conditions. Common applications of Aluminum 5083 in marine industries include:

• Shipbuilding: Aluminum 5083 is extensively used in shipbuilding for hulls, decks, and bulkheads. Its high strength and excellent corrosion resistance make it ideal for parts that are constantly exposed to seawater.
• Offshore Structures: The alloy’s robustness and resistance to saltwater corrosion make it perfect for offshore structures like oil rigs and platforms.
• Marine Components: Aluminum 5083 is used for various marine components such as propellers, rudders, and other structural elements that demand durability and resistance to impacts.

Comparative Analysis of Applications in Marine Industries

When comparing Aluminum 5005 and 5083 for marine use, key points include corrosion resistance, strength, and suitability for specific applications:

• Corrosion Resistance: Aluminum 5083 offers superior corrosion resistance, particularly in saltwater environments. Aluminum 5005, while adequate for less demanding conditions, requires additional protection in harsh marine settings.
• Strength and Durability: Aluminum 5083’s higher tensile and yield strength make it more suitable for structural applications where durability is crucial. Aluminum 5005, with its lower strength, is better suited for non-structural and interior components.
• Formability and Weldability: Aluminum 5005 excels in formability, making it ideal for applications requiring complex shapes. Aluminum 5083, though less formable, is highly weldable, which is advantageous for constructing large marine structures.

Practical Applications

In the marine industry, selecting the appropriate aluminum alloy depends on the specific requirements of the application. Aluminum 5083 is preferred for high-stress environments requiring robust corrosion resistance and strength, while Aluminum 5005 is suitable for less demanding applications where formability and aesthetics are more critical.

Applications in Aerospace Industries

Importance of Material Selection for Aerospace Applications

Material selection is crucial in the aerospace industry due to the demanding requirements for strength, weight, durability, and resistance to environmental factors. Aluminum alloys, particularly Aluminum 5005 and 5083, are popular choices for various aerospace applications because of their favorable properties.

Suitability of Aluminum 5005 for Aerospace Applications

Aluminum 5005 is ideal for applications that prioritize formability and corrosion resistance over high strength.

• Non-Structural Components: Aluminum 5005 is commonly used in non-structural components due to its moderate strength. It is ideal for parts that do not bear significant loads but require good corrosion resistance, such as interior panels and decorative elements.
• Ease of Machining: The alloy’s good machinability allows it to be easily fabricated into complex shapes, suitable for intricate designs and aesthetic components within the aircraft, though its corrosion resistance is less robust in aggressive environments, limiting its use in critical structural applications.

Suitability of Aluminum 5083 for Aerospace Applications

Aluminum 5083 is preferred for high-stress applications due to its superior strength and corrosion resistance.

• Structural Components: The high tensile and yield strengths of Aluminum 5083 make it suitable for structural components that are subjected to significant mechanical loads. It is often used in the construction of fuselage frames, wings, and other load-bearing parts.
• Welding and Post-Weld Strength: Aluminum 5083 retains its strength after welding, ensuring the integrity of welded aerospace structures. This characteristic ensures the durability and reliability of the final components.
• Corrosion Resistance: Its excellent resistance to corrosion, especially in marine and industrial environments, makes it ideal for aerospace applications where exposure to harsh conditions is expected.

Comparative Analysis of Applications in Aerospace Industries

Comparing Aluminum 5005 and 5083 for aerospace use reveals their distinct advantages and limitations:

• Strength and Load-Bearing Capacity: Aluminum 5083 outperforms 5005 in terms of tensile and yield strength, making it more suitable for critical structural applications. The higher strength of 5083 ensures it can withstand the mechanical stresses encountered during flight.
• Formability and Fabrication: Aluminum 5005 excels in formability, allowing it to be easily shaped into complex and detailed components. This quality makes it perfect for aesthetic and interior components requiring intricate designs. In contrast, 5083, while still formable, requires more force to shape, limiting its use in highly detailed applications.
• Corrosion Resistance: In environments where corrosion resistance is paramount, such as marine and certain aerospace applications, Aluminum 5083 is the better choice due to its higher resistance to corrosive elements. Aluminum 5005, though corrosion-resistant, is more suited for less aggressive environments.
• Weldability: Both alloys are weldable, but Aluminum 5083’s ability to retain strength after welding gives it an advantage in the construction of large, welded structures. This property is essential for ensuring the long-term performance and safety of aerospace components.

Practical Applications

In the aerospace industry, the choice between Aluminum 5005 and 5083 depends on the specific requirements of the application. Aluminum 5005 is favored for its formability and moderate corrosion resistance in non-structural applications, while Aluminum 5083 is chosen for its superior strength and durability in critical structural components.

Real-life Case Studies

Architectural Applications

Aluminum 5005 is widely used in architectural projects due to its excellent formability and ability to be anodized. One notable example is its use in the cladding of modern buildings. Its ability to be anodized allows for a variety of finishes, enhancing both aesthetic appeal and durability. For instance, the exterior panels of the Louvre Abu Dhabi utilize Aluminum 5005, chosen for its capability to form intricate shapes and provide a visually appealing finish that withstands the harsh environmental conditions of the region.

Transportation Sector

In the transportation sector, Aluminum 5005 is utilized for manufacturing vehicle body panels. A leading automobile manufacturer uses 5005 aluminum for lightweight body panels, which improves fuel efficiency. The moderate strength and excellent formability of 5005 make it ideal for producing complex shapes required in vehicle design, ensuring both functionality and aesthetic quality.

Marine Applications

Aluminum 5083 is renowned for its superior corrosion resistance and high strength, making it a prime choice in marine applications. A key example is its use in building high-speed ferries and naval vessels. For instance, many modern patrol boats have hulls made of 5083 aluminum, which resists saltwater corrosion, ensuring long-lasting durability and reliability.

Aerospace Industry

In the aerospace industry, Aluminum 5083’s high strength and excellent weldability are critical. A notable application is in the manufacturing of aircraft structural components. The Airbus A400M uses 5083 aluminum in its fuselage and wings. The alloy’s high strength-to-weight ratio and resistance to stress-corrosion cracking make it ideal for maintaining structural integrity and performance during demanding flight operations.

Frequently Asked Questions

Below are answers to some frequently asked questions:

What are the key differences between Aluminum 5005 and 5083?

Aluminum 5005 and 5083 are distinct aluminum alloys with unique properties and applications. The primary difference lies in their chemical composition and mechanical properties. Aluminum 5005 contains 0.5-1.1% magnesium, contributing to its relatively low strength and good corrosion resistance. It is well-suited for decorative applications due to its excellent appearance and machinability.

In contrast, Aluminum 5083 has a higher magnesium content of 4.0-4.9%, which imparts significantly higher strength and exceptional corrosion resistance, especially in marine environments. This makes it ideal for high-strength applications such as shipbuilding and automotive components. Additionally, 5083’s higher rigidity and hardness provide better wear and impact resistance compared to 5005.

Which aluminum alloy is better for marine applications?

When considering aluminum alloys for marine applications, 5083 aluminum generally stands out as the better option compared to 5005. This is due to its superior mechanical strength, higher magnesium content, and exceptional corrosion resistance, particularly in harsh seawater environments. The high magnesium content in 5083 forms a robust oxide layer that enhances its resistance to seawater corrosion, making it ideal for critical structures such as hulls and decks in marine vessels.

On the other hand, while 5005 aluminum offers good formability and is easier to machine, it has lower strength and less effective corrosion resistance in seawater conditions. Therefore, it is more suitable for freshwater or less demanding marine applications where high formability is a priority but extreme strength and corrosion resistance are not as critical.

How do the formability and machinability of Aluminum 5005 and 5083 compare?

When comparing the formability and machinability of Aluminum 5005 and 5083, Aluminum 5005 generally offers better formability due to its excellent ductility and cold workability. This makes it suitable for applications requiring high flexibility, such as sheet metal work and appliances. On the other hand, Aluminum 5083, while still formable, is more challenging to shape because of its higher strength, which can require specialized equipment for bending and forming.

In terms of machinability, Aluminum 5005 is easier to machine due to its medium strength and fine-grained structure, making it ideal for general machining tasks. Conversely, Aluminum 5083, being stronger and harder, poses more challenges in machining, necessitating more powerful equipment and potentially causing greater tool wear. This makes 5083 more suited for heavy-duty structural components where its strength is an asset despite the machining difficulties.

How should one choose the best aluminum alloy for specific project requirements?

Choosing the best aluminum alloy for specific project requirements involves evaluating several critical factors such as corrosion resistance, strength, workability, weldability, and cost. When comparing Aluminum 5005 and 5083, these considerations are essential to determine the most suitable material for your application.

Aluminum 5005, with approximately 0.8% magnesium, offers moderate tensile strength (20-30 ksi) and excellent corrosion resistance, making it ideal for architectural and decorative applications. Its good formability and weldability add to its versatility in fabrication processes.

On the other hand, Aluminum 5083, containing 4.0% magnesium, 0.45% manganese, and 0.15% chromium, provides higher tensile strength (40-54 ksi) and exceptional resistance to seawater corrosion. This makes it particularly suitable for marine components and other welded assemblies that require superior strength and durability.

What are the cost and sustainability considerations for Aluminum 5005 and 5083?

When comparing the cost and sustainability considerations of Aluminum 5005 and 5083, several factors come into play.

Cost Considerations:
Aluminum 5005 is generally more affordable, with prices ranging between $3.09 and $3.69 per pound. In contrast, Aluminum 5083 typically costs between $2.60 and $3.00 per kilogram for smaller quantities, with bulk orders priced between $2,600 and $2,800 per ton. The higher price of 5083 is due to its superior properties, such as strength and corrosion resistance.

Sustainability Considerations:
Both alloys are highly recyclable, which helps reduce waste and energy consumption compared to producing new aluminum from raw materials. Aluminum 5083, with its exceptional durability and corrosion resistance, offers a longer lifespan in harsh environments, decreasing the need for frequent replacements and lowering the overall environmental impact. This extended lifespan contributes to a reduction in resource consumption and waste generation over time.

How does the weldability of Aluminum 5005 compare to Aluminum 5083?

Aluminum 5005 and 5083 differ significantly in weldability due to their composition and mechanical properties. Aluminum 5005, with a lower magnesium content (0.5% to 1.1%), is easier to weld and poses fewer challenges related to stress corrosion cracking. However, it does not offer the same weld strength as Aluminum 5083.

Aluminum 5083, containing 4.0% to 4.9% magnesium, is known for its exceptional weldability and is often used in demanding applications such as shipbuilding. It is typically welded using filler alloys like 5356 or 5183, which provide excellent mechanical properties and corrosion resistance. However, 5083 can be susceptible to stress-corrosion cracking if exposed to high temperatures for extended periods.

Overall, Aluminum 5083 generally outperforms Aluminum 5005 in weldability due to its higher strength and suitability for heavy-duty applications, although both alloys can be effectively welded with appropriate techniques and fillers.