Abstract A fine-grained fusion zone characterises a tough aluminium weld. To improve the solidification characteristics and refine the grains in aluminium welding, different inoculation particle combinations were introduced to the filler wire by solid state metal screw extrusion. Filler wires were I-joint welded with two different welding methods to reveal the potency for grain refinement. Grain size, microstructure, porosity content, and hardness across the weld was revealed. Gas metal arc welding with a Ti-TiC inoculated filler wire exhibited a remarkable grain refinement of 91% compared to a base reference of commercial pure aluminium. The Al $$_3$$ 3 Ti intermetallic phase was found as nucleation point. Gas tungsten arc welding showed lower grain refinement potency, and no Al $$_3$$ 3 Ti phase was found in any weld. Thus, the effect of welding method must be taken into consideration upon development of inoculant containing filler wires.