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OEM/ODM ER1100 Aluminum Welding Wire Manufacturers

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ER1100 Aluminum Welding Wire
  • ER1100 Aluminum Welding Wire
  • ER1100 Aluminum Welding Wire
  • ER1100 Aluminum Welding Wire
  • ER1100 Aluminum Welding Wire
  • ER1100 Aluminum Welding Wire
Aluminum Welding Wire

ER1100 Aluminum Welding Wire

1100 is about 99% pure Aluminum filler metal, which has excellent processability, higher corrosion resistance and tenacity, for welding 1000 series alloy metal mainly. Because of the soft performance, the feed status should be careful in MIG welding.

Mainly apply to high voltage bus, distribution box, heat exchanger, chemical and food etc.

E-mail: rich@chinayinyu.com
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ER1100
99.0% Al
Aluminum Welding Wire
1xxx Series · Commercial Purity
AWS A5.10
ISO 18273
≥99.0%Aluminum Purity
643-657°CMelting Range
2.71 g/cm³Density
62% IACSConductivity
Product Overview
ER1100 is a high-purity aluminum filler metal containing a minimum of 99.0% aluminum. It is specifically designed for gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) applications where high electrical and thermal conductivity are required. The wire undergoes precision shaving and chemical cleaning to remove surface oxides and residual lubricants, ensuring stable arc characteristics. ER1100 offers excellent corrosion resistance in many industrial environments and provides color matching capability after anodizing. It is the preferred filler metal for welding 1xxx series aluminum alloys and is widely used in electrical, chemical, and architectural applications.
ER1100 Aluminum Welding Wire
Core Advantages
High Conductivity99.0% minimum aluminum content provides superior electrical and thermal conductivity for heat exchange and electrical transmission applications.
Corrosion ResistanceHigh purity aluminum offers excellent resistance to organic acids, salts, and specific industrial chemicals.
Anodic Color MatchPure aluminum composition allows for uniform anodized finish between weld bead and base material.
DuctilityWeld metal remains soft and formable, facilitating post-weld bending and forming operations.
Specification Data
Wire Diameters0.8mm · 1.0mm · 1.2mm · 1.6mm
Surface FinishShaved · Chemically degreased
PackagingD200 (2kg) · D300 (7kg) · K415 (50kg)
Shielding Gas100% Argon (99.996%)
ComplianceAWS A5.10 ER1100
ER1100 Detail
Chemical Composition Limits
Aluminum (Al)≥ 99.0%
Copper (Cu)≤ 0.05%
Silicon (Si)≤ 0.10%
Iron (Fe)≤ 0.20%
Zinc (Zn)≤ 0.05%
Others≤ 0.15% total
Total impurities below 0.15% · Meets AWS A5.10 requirements for ER1100
Application Scenarios
ElectricalBusbars, electrical connectors, capacitor foils, transformer windings
Chemical ProcessingStorage tanks, piping systems, food processing equipment
Heat ExchangeRadiators, cooling fins, HVAC components, thermal conductors
ArchitecturalDecorative panels, extruded profiles, anodized trim components
Frequently Asked Questions
What base materials can ER1100 weld?
ER1100 is designed for welding 1xxx series aluminum alloys (1100, 1050, 1060) and is also suitable for joining aluminum to itself in applications where high purity and conductivity are required.
Does ER1100 require special shielding gas?
100% Argon with a minimum purity of 99.996% is recommended. For thicker sections, Argon-Helium mixtures can improve penetration and wetting characteristics.
Can ER1100 be anodized after welding?
Yes, ER1100 provides excellent color matching capability during post-weld anodizing due to its high-purity aluminum composition, producing uniform appearance between weld and base metal.
What causes porosity when welding with ER1100?
Porosity is typically caused by moisture contamination on the wire surface, inadequate cleaning of base material, or insufficient shielding gas coverage. Store wire below 55% humidity and ensure proper gas flow rates.
Storage Conditions
Store ER1100 wire in original vacuum-sealed packaging at 10-35°C with relative humidity below 55%. Opened spools must be used within 96 hours. For extended storage, place in heated cabinet at 35-45°C. Prevent exposure to oil mist, grinding dust, or chemical vapors.
Usage Precautions
Use clean, powder-free gloves when handling wire. Ensure base material is thoroughly cleaned of oxides and grease using stainless steel brushes or chemical degreasers. Use U-groove drive rolls and Teflon liners for optimal feeding performance.
Technical data represents typical values. Actual performance depends on welding procedure, base material condition, and joint configuration. Procedure qualification recommended for critical applications.

  • GB/T 10850

    S AL 1100

    DIN EN ISO 18273

    S AL 1100 (Al99.0Cu)

    AWS/ASME A 5.10

    ER 1100, R1100

    CHEMICAL COMPOSITION（wt）/%

    Si

    Fe

    Cu

    Mn

    Mg

    Cr

    Zn

    Ti

    Be

    other

    Al

    single

    total

    ≤0.45

    ≤0.05-0.20

    ≤0.05

    ..

    ..

    ≤0.10

    ..

    ≤0.0003

    ≤0.05

    ≤0.15

    Rem.

    TYPICAL CHARACTERISTICS  

    melting range

    1100 - 1200°F

    density

    2.7g/mm3

    corrosion resistance

    A(Gen) A(SCC)

    coefficient of thermal expansion（20℃~300℃）

    23.7×10-6/K

    Color after electrode oxidization

    white

    The mechanical properties of typical welded joint

    Starting Sheet

    Starting Sheet Performance

    Joint Performance

    Rm (MPa)

    RP0.2 (MPa)

    A/%

    Rm (MPa)

    RP0.2 (MPa)

    A/%

    5456-H112

    315

    165

    22

    310

    160

    14

    Size and Packet 

    Class

     Typical Diameter/mm

    Reference Packet/Kg

    MIG

    0.8、0.9、1.0、1.2、1.6、2.4

    0.5、2、5、6、7、9

    TIG

    1.6、2.0、2.4、3.0、3.2、4.0、5.0/1000

    5、10、20

    COIL

    2.4、3.0、3.2、4.0

    8-15

    DRUM

    0.8、0.9、1.0、1.2、1.6

    40、80
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ER1100 Aluminum Welding Wire

Coming From China，
Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is located in the industrial zone of Puyang Town, Xiaoshan District, Hangzhou, Zhejiang Province. It is a high-technology and high-performance China Aluminum Welding Wire Manufacturers and wholesale ER1100 Aluminum Welding Wire factory. The company has more than 20 years of aluminum alloy wire production experience, with international advanced aluminum alloy welding wire manufacturing equipment, complete testing equipment, stable production process and strict quality control system. The high-performance OEM/ODM ER1100 Aluminum Welding Wire produced by the company has successfully passed a number of international authoritative certification, such as DB, CE, ABS, DNV, CCS, etc. We have more than 200MT production capacity per month and 50% was exported to over 30 countries such as USA, Mexico, Southeast Asia, Japan, Korea, Australia, New Zealand and etc.

  • 30+

    USED IN HEAVY INDUSTRY TECHNOLOGY SECTOR

  • 35

    YEARS OF RESEARCH AND DEVELOPMENT EXPERIENCE

  • 200+

    COOPERATIVE LARGE-SCALE R & D INSTITUTIONS

  • 20+

    GLOBAL TRADE COUNTRIES AND REGIONS

Coming From China,
Marketing To The World.

More than 90% of our field operators have professional and technical education background, and have many years of experience in equipment processing and assembly. It is precisely because of this united, dedicated, pioneering, skilled and experienced team that the company's technology and products can be continuously updated and improved.

Honor

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Industry Information Extension

Automotive Lightweighting Trends: How ER1100 Aluminum Welding Wire Supports EV Battery Tray Welding

The push for electric vehicle (EV) lightweighting has made high-purity aluminum welding a critical process in manufacturing. Among the top filler metals for this application, ER1100 aluminum welding wire stands out due to its 99% minimum aluminum content, making it ideal for joining 1060, 1070, and 1100 aluminum alloys—common materials in EV battery enclosures and trays.

Why ER1100 is the Preferred Choice for EV Battery Trays?

Unlike ER4043 or ER5356 aluminum filler wires, which contain silicon or magnesium, ER1100 TIG and MIG welding wire offers superior corrosion resistance and electrical conductivity—key factors for battery tray durability. Additionally, its low melting point (1,220°F/660°C) and excellent weldability minimize heat distortion, crucial for thin aluminum sheets used in lightweight EV structures.

Key Advantages of ER1100 in EV Manufacturing

High Ductility & Formability: Ensures crack-free welds in deep-drawn aluminum battery housings.
Minimal Intermetallic Formation: Unlike silicon-based wires (e.g., ER4043 filler metal), ER1100 reduces brittleness in welds.
Compliance with AWS A5.10 Standards: Meets stringent automotive welding specifications for safety-critical components.

Performance Comparison: ER1100 vs. Other Aluminum Filler Wires

Parameter ER1100 ER4043 ER5356
Aluminum Content 99%+ 92-95% 93-96%
Tensile Strength 13 ksi 24 ksi 30 ksi
Best For Pure Al alloys (1060, 1100) 6xxx series (6061) 5xxx series (5052, 5083)
Corrosion Resistance ⭐⭐⭐⭐⭐ ⭐⭐⭐ ⭐⭐⭐⭐
Electrical Conductivity Excellent Good Moderate
Typical Applications EV battery trays, chemical tanks Structural automotive parts Marine applications

Emerging Trends: ER1100 in Next-Gen Battery Trays

With automakers like Tesla and BYD adopting ultra-light battery designs, demand for low-porosity aluminum welding wire is rising. ER1100’s compatibility with pulsed MIG welding and automated robotic welding systems makes it a cost-effective solution for high-volume EV production.