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.
The ER1100 Aluminum Welding Wire is engineered for precision aluminum welding applications. It provides consistent arc performance and excellent weldability for aluminum alloy fabrication, including automotive components, marine structures, and industrial equipment. The wire is compatible with TIG and MIG welding processes, ensuring uniform penetration and stable bead formation.
| Parameter | Specification | Unit |
| Wire Type | ER1100 | - |
| Diameter | 0.8, 1.0, 1.2, 1.6, 2.0 | mm |
| Aluminum Content | ≥99.0% | % |
| Ultimate Tensile Strength | ≥110 MPa | MPa |
| Elongation | ≥12% | % |
| Melting Point | ≈660 | °C |
| Spool Weight | 5, 15, 20 | kg |
The ER1100 Aluminum Welding Wire is compatible with both TIG and MIG welding techniques. For thin sheets and precise joints, TIG welding is recommended due to its controlled heat input. For medium to thick sections requiring higher deposition rates, MIG welding provides efficient material transfer and stable arc performance. Hangzhou Kunli welding materials Co., Ltd. ensures that each spool meets tight tolerances to support consistent weld quality across both processes.
This wire is widely used in aluminum alloy fabrication for automotive panels, marine equipment, industrial machinery, and structural components. The high purity and consistent composition of ER1100 allow it to preserve base material properties while providing reliable weld penetration. Hangzhou Kunli welding materials Co., Ltd. leverages over 20 years of aluminum alloy wire production experience, advanced manufacturing equipment, and strict quality control to supply both domestic and international clients, supporting large-scale production requirements.
The company operates with a stable production process and complete testing equipment, ensuring each batch of ER1100 Aluminum Welding Wire complies with international certifications such as DB, CE, ABS, DNV, and CCS. With a monthly production capacity exceeding 200MT and collaborations with research institutes like Beijing Nonferrous Metals Research Institute and Central South University, Hangzhou Kunli welding materials Co., Ltd. guarantees technical consistency, process stability, and reliable supply to both domestic and overseas markets, including USA, Mexico, Southeast Asia, Japan, Korea, Australia, and New Zealand.
USED IN HEAVY INDUSTRY TECHNOLOGY SECTOR
YEARS OF RESEARCH AND DEVELOPMENT EXPERIENCE
COOPERATIVE LARGE-SCALE R & D INSTITUTIONS
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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.
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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.
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.
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.
| 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 |
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.