The horizontal continuous casting process with the heating mold was adopted for fabricating defect-free 4043 Al alloy rods of 3.2m dia. with mirror surfaces. These rods were drawn into 2.4mm dia. rods for GTAW welding. The GTAW welding tests were carried out by use of these welding rods with 6061 Al alloy as a base metal. After welding, the X-ray tests, tensile strength tests, bending tests, and microstructural analysis of welded zone and HAZ were carried out. The results represented that the welding rods with good surfaces and welding properties could be made by the horizontal continuous casting, and followed by the drawing process.