Investigation on the microstructure and mechanical properties of 5356 aluminum alloy wire in continuous casting direct rolling process

5356 aluminum alloy welding wire is widely used in automotive, aerospace, and marine, due to its excellent corrosion resistance, high strength-to-weight ratio, and excellent weldability. The properties of aluminum alloys are primarily determined by their microstructure. This study investigates the microstructure evolution, mechanical properties, and texture of 5356 aluminum alloy welding wire produced using the continuous casting direct rolling (CCDR) method. The results show that continuous rolling led to an increased generation of dislocations in the matrix, and dynamic recovery plays an important role in reducing dislocation density. As a result of dynamic recovery, the microstructures of 3RPs consist of extensive deformed grains and numerous substructures. The continuous casting direct rolling textures are characterized to be cube and shear textures. After 10 rolling processes, the 5356 aluminum alloy welding wire shows a highest tensile strength of 365 MPa with a lowest elongation of 8.8%. This research provides theoretical guidance to produce high-performance 5356 aluminum alloy welding wires, paving the way for their more efficient and reliable applications.