ER1100 Aluminum Welding Wire

ER1100 Aluminum Welding Wire – High-Purity Filler for Conductivity and Corrosion Resistance

As a Er1100 Aluminum Welding Wire.html manufacturer, we match product configuration to the application, operating limits, interfaces and acceptance criteria defined for each project.

Hangzhou Kunli Welding Materials Co., Ltd. is a China-based manufacturer and supplier of ER1100 aluminum welding wire, engineered for applications where electrical conductivity, corrosion resistance, and anodized color match are critical. With over 20 years of aluminum alloy wire production experience, we supply this commercial-purity filler metal to fabricators, OEMs, and distributors worldwide.

Our ER1100 wire meets AWS A5.10 and ISO 18273 standards, with a minimum aluminum content of 99.0%. It is available in MIG spools, TIG straight rods, coils, and drums, configured to your welding process and production volume.

Product Overview

ER1100 is a 1xxx series filler metal with a nominal composition of 99.0% aluminum. It is designed for gas metal arc welding (GMAW/MIG) and gas tungsten arc welding (GTAW/TIG) of 1000 series aluminum alloys, including 1100, 1050, and 1060. The wire is precision shaved and chemically cleaned to remove surface oxides and lubricants, ensuring stable arc characteristics and minimal porosity.

Key properties include a melting range of 643–657°C, density of 2.71 g/cm³, and electrical conductivity of approximately 62% IACS. These characteristics make it ideal for heat exchangers, electrical busbars, chemical storage tanks, and architectural trim.

Applications and Fit

ER1100 is the preferred filler for joining 1xxx series alloys in industries where purity and conductivity are paramount. Typical applications include:

• Electrical: Busbars, connectors, capacitor foils, transformer windings – where high conductivity is essential.
• Chemical Processing: Storage tanks, piping, food processing equipment – benefiting from excellent corrosion resistance to organic acids and salts.
• Heat Exchange: Radiators, cooling fins, HVAC components – leveraging thermal conductivity.
• Architectural: Decorative panels, extruded profiles, anodized trim – where color match after anodizing is required.

For EV battery tray welding, ER1100 offers high ductility and minimal intermetallic formation, reducing brittleness in thin aluminum structures.

Specifications and Compliance

Chemical composition limits (wt%): Al ≥99.0, Cu ≤0.05, Si ≤0.10, Fe ≤0.20, Zn ≤0.05, others ≤0.15 total. These limits ensure consistent weld quality and corrosion performance.

Available Configurations

We supply ER1100 in multiple forms to match your welding process and production requirements:

• MIG Wire: Diameters 0.8, 0.9, 1.0, 1.2, 1.6, 2.4 mm; spool weights 0.5, 2, 5, 6, 7, 9 kg.
• TIG Rods: Diameters 1.6, 2.0, 2.4, 3.0, 3.2, 4.0, 5.0 mm; lengths 1000 mm; bundles 5, 10, 20 kg.
• Coils: Diameters 2.4, 3.0, 3.2, 4.0 mm; weights 8–15 kg.
• Drums: Diameters 0.8, 0.9, 1.0, 1.2, 1.6 mm; weights 40, 80 kg.

Standard packaging includes D200 (2 kg), D300 (7 kg), and K415 (50 kg) spools. Custom diameters and packaging are available for OEM/ODM projects.

Welding Performance and Shielding Gas

For MIG welding, use 100% argon with a minimum purity of 99.996%. For thicker sections, argon-helium mixtures improve penetration and wetting. The wire's clean surface ensures stable arc and low spatter.

Due to the soft nature of pure aluminum, feeding requires U-groove drive rolls and Teflon liners to prevent bird-nesting. We recommend using a push-pull system for long conduit lengths.

Quality Assurance and Testing

Our factory is ISO9001, ISO14000, and ISO18001 certified. We operate a testing lab equipped with SHIMADZU PDA 5500 optical emission spectrograph, metallographic microscope, tension tester, and welding robots (OTC A-V6, Panasonic YD-400GE) to verify chemical composition, mechanical properties, and weldability.

Each production lot is tested for composition and mechanical performance. We provide material test certificates upon request.

Information We Use to Configure Your Solution

To prepare a precise quotation and configuration, we need the following project details:

• Welding process (MIG or TIG) and base material alloy
• Wire diameter and packaging preference (spool, coil, drum)
• Required quantity per order and annual volume
• Any specific standards or certifications (e.g., AWS, ISO, customer-specific)
• Delivery destination and Incoterms preference

Our engineering team will confirm the appropriate alloy, diameter, and packaging to match your application.

Storage and Handling

Store ER1100 in original vacuum-sealed packaging at 10–35°C with relative humidity below 55%. Opened spools should be used within 96 hours. For extended storage, use a heated cabinet at 35–45°C. Avoid exposure to oil mist, grinding dust, or chemical vapors.

Related Products

Explore our other aluminum filler metals: ER4043 Silicon Aluminum Welding Wire, ER4047 Aluminum MIG Welding Wire, and ER5356 Aluminum Welding Wire. For the full range, visit our Aluminum Welding Wire category.

FAQs

What base materials can ER1100 weld?

ER1100 is designed for 1xxx series alloys (1100, 1050, 1060) and can join aluminum to itself where high purity and conductivity are required.

Does ER1100 require special shielding gas?

100% argon (99.996% purity) is recommended. For thicker sections, argon-helium mixtures improve penetration.

Can ER1100 be anodized after welding?

Yes, its high-purity composition provides excellent color match during post-weld anodizing.

What causes porosity when welding with ER1100?

Porosity is typically from moisture on the wire, unclean base material, or insufficient gas coverage. Store wire below 55% humidity and ensure proper gas flow.

What packaging options are available?

We offer spools (2–9 kg), coils (8–15 kg), and drums (40–80 kg). Custom packaging is available for OEM orders.