Aluminum welding wire is a solid alloy wire designed for automatic wire feeding systems (MIG/TIG), offering faster welding speeds than stick welding rods used in SMAW (Shielded Metal Arc Welding) and better cost efficiency than TIG filler rods (Gas Tungsten Arc Welding). With less manual work required, it is ideal for automated and high-volume production. High-quality welding wire is essential for achieving strong, clean welds.
Chalco aluminum welding wires—including 4043, 5356, 5556, 5183, and other alloys—are certified to ISO 9001 and IATF 16949 and meet AWS A5.10 and ISO 18273 standards. Chalco also provides full documentation such as COA, MSDS, COC, and RoHS to ensure customers' confidence in product quality. This strict quality control ensures excellent welds with minimal spatter, making them widely used in automotive, shipbuilding, rail, and other industries.
Chalco aluminum welding wire product introduction
Alloy series: 4043, 5356, 5556, 5183, 4643, 4943, 4047, 5554, 1100 Click to [alloy detail]
Welding Methods: MIG (manual/automatic/flux-cored), TIG with automatic wire feed
Welding Positions: flat, horizontal, vertical (up/down), overhead
Surface Finish: bright silver, brushed, optional anti-oxidation coating
Common Diameters: 0.030" (0.8mm), 0.035" (0.9mm), 0.045" (1.2mm), 1/16" (1.6mm), 3/64" (1.2mm), 5/64" (2.0mm), etc.
Wire Condition/Tolerance: F temper; ISO 544 h9 ±0.02mm
Packaging: 0.5kg, 1kg, 5kg, 15kg spools; 300mm/400mm cores; custom large spools (50-250kg) and packaging tailored to MIG torch systems
Chalco aluminum welding wire hot selling products
In order to meet the diverse needs of different welding projects for strength, crack resistance, corrosion resistance and processing performance, Chalco provides a variety of aluminum welding wire products, covering mainstream and functional alloys, which are widely used in structural welding, precision welding and high-strength welding scenarios.
Top choice for welding: 4043 and 5356 —— Best-selling aluminum welding wires
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4043 aluminum welding wire
Welding system: MIG (standard, automatic, robotic); pure argon or argon-helium gas
Applications: Structural aluminum welding in industrial and transportation sectors
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5356 aluminum welding wire
Welding system: MIG (standard, automated, robotic); pure argon gas
Applications: Aluminum welding in marine, automotive, and heavy machinery industries
- Lower melting point, good weld pool flow
- Strong resistance to hot cracking
- Less spatter, smooth and neat weld bead
- Weld bead can be anodized gray or dark gray
- High weld strength and load capacity
- Excellent corrosion resistance, ideal for marine environments
- Good weld metal ductility, better crack resistance than standard Al-Mg wires
- Weld bead color close to base metal, good for decorative use
4643 aluminum welding wire
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4643 aluminum welding wire is an Al-Si-Mg alloy offering the fluidity of 4043 with improved anodizing color match, ideal for visible structural welds.
Welding system: MIG with standard or robotic feeding systems.
Recommended application: Decorative and structural parts requiring anodizing, such as curtain walls, window frames...
- Excellent anodizing compatibility with weld color close to base metal
- Good weldability and low risk of hot cracking
- Stable arc performance, easy to operate with smooth bead appearance
- Moderate weld strength, suitable for medium-load structural connections
4943 aluminum welding wire
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4943 aluminum welding wire is an Al-Si-Mg-Zr alloy offering upgraded strength over 4043 with excellent fluidity and crack resistance, ideal for high-strength 6xxx series welds.
Welding system: MIG with standard or automated feeding; use pure argon.
Recommended application: High-strength structural welding of 6xxx series parts, e.g. mechanical components, chassis, rail vehicle parts...
- The weld strength is better than 4043 and close to the 6061 base material strength
- Good weld ductility and reliable crack resistance
- Stable welding process, low spatter and good forming effect
- Support anodizing, the weld color performance is better than 4043
5183 aluminum welding wire
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5183 aluminum welding wire is a high-magnesium alloy providing superior weld strength and seawater corrosion resistance, preferred for marine and structural applications.
Welding system: MIG welding with manual/automated systems; pure argon.
Recommended application: Marine and corrosion-resistant structural welding, such as ship decks, offshore platforms, storage tanks...
- High weld strength, close to the parent material strength
- Excellent seawater corrosion resistance, especially suitable for marine environment
- Weld metal has good toughness and strong impact fatigue resistance
- The fluidity is stable during welding and the forming effect is reliable
5556 aluminum welding wire
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5556 aluminum welding wire is a high-strength Al-Mg alloy offering superior fatigue resistance and stability for demanding structural welding tasks.
Welding system: MIG with standard/automated/heavy-load setups; use pure Ar.
Recommended application: Military, aerospace, and industrial structures requiring high load capacity...
- The weld strength is higher than 5356, suitable for high load structures
- Adapt to the base material in heat treatment state, and the strength remains stable after welding
- Excellent fatigue performance, suitable for repeated shock and vibration environment
- With certain corrosion resistance, suitable for marine and industrial environment applications
4047 aluminum welding wire
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4047 aluminum welding wire is a high-silicon aluminum alloy with excellent flow and airtight welds, ideal for casting repair and precision sealing applications.
Welding system: MIG with automatic feeding & precision setups; pure Ar advised.
Recommended application: Ideal for heat exchangers, evaporators, aluminum casting repairs, and sealed structural welding...
- Lower melting point, excellent welding fluidity, uniform forming
- Thermal crack resistance is better than 4043, suitable for complex joints
- Good airtightness, suitable for welding sealed containers and liquid cooling components
- Can be used to repair aluminum castings, with beautiful welding and not easy to collapse
More optional aluminum alloy and welding wire alloy customization services
Beyond standard 4043 and 5356 alloys, Chalco offers a broad range of aluminum and specialty welding wires to meet diverse needs—whether for corrosion resistance, high-strength welds, anodizing color match, casting repair, conductivity, or aerospace use. We also support custom alloy development and supply select non-aluminum wires like aluminum bronze, copper, and nickel-aluminum for multi-metal applications.
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1100 al welding wire
1100 is a pure aluminum welding wire for 1050, 1060, and 1070 alloys, offering good ductility and conductivity—ideal for low-strength joints, electrical parts, and decorative welds.
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6061 al welding wire
Though mainly used as base material, 6061 is also available as welding wire for specific self-welding or custom jobs requiring precise composition match with the base metal.
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5554 al welding wire
A medium-strength aluminum-magnesium wire for welding 5454 and 5554 alloys, commonly used in fuel tanks, marine parts, and other corrosion-resistant applications.
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Aluminum bronze welding wire
Offers excellent corrosion resistance and strength; used for repairing copper alloy parts like pumps and valves, and for copper-aluminum transition joints.
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Copper alloy welding wire
Suitable for welding copper, copper alloys, and copper-stainless steel; known for great conductivity in electrical, thermal, and precision applications.
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Nickel-aluminum welding wire
Resistant to high temperatures and corrosion; ideal for surfacing and structural repairs in power plants, nuclear facilities, and wear-prone alloy parts.
If you cannot fully match the existing welding wire products in your actual project, please contact Chalco's technical team for customized solutions or recommended alternative alloys. Quick Quote
Chalco aluminum welding wire products technical parameters and implementation standards
| Chalco aluminum welding wire products chemical composition comparison table (typical value, unit: %) | |||||
| element | 4043 (AlSi5) | 5356 | 4943 | 5183 | 5556 |
| Si | 4.5–6.0 | ≤0.25 | 4.0–5.0 | ≤0.25 | ≤0.25 |
| Mg | – | 4.5–5.5 | 0.05–0.3 | 4.3–5.0 | 4.7–5.5 |
| Mn | – | 0.05–0.2 | ≤0.15 | 0.5–1.0 | 0.05–0.2 |
| Fe | ≤0.8 | ≤0.4 | ≤0.6 | ≤0.4 | ≤0.4 |
| Cu | ≤0.3 | ≤0.1 | ≤0.3 | ≤0.1 | ≤0.1 |
| Zn | ≤0.1 | ≤0.25 | – | ≤0.25 | ≤0.25 |
| Ti | ≤0.2 | ≤0.2 | – | ≤0.2 | ≤0.2 |
| other | ≤0.15 | ≤0.15 | ≤0.15 | ≤0.15 | ≤0.15 |
| Al | margin | margin | margin | margin | margin |
| The specific composition is subject to the product batch COA, and alloy fine-tuning and special composition customization are supported. | |||||
| Chalco aluminum welding wire products weld mechanical properties (reference value) | |||
| alloy | Tensile strength (MPa) | Yield strength (MPa) | Elongation (%) |
| 4043 Weld | 170–190 | 90–110 | 6–10 |
| 5356 Weld | 250–280 | 110–130 | 11–18 |
| 4943 Weld | 230–260 | 130–150 | 10–14 |
| 5183 Weld | 270–300 | 130–160 | 10–16 |
| 5556 Weld | 280–310 | 150–180 | 8–12 |
| The weld performance varies with the thickness of the base material, welding process and heat treatment status. The above are reference values for standard test plate tests. | |||
| Aluminum Welding Wire Key Process Parameters Reference Table | |||||||
| Welding Wire Model | Typical Diameter (mm) | Recommended Current Range (A) | Recommended Voltage Range (V) | Wire Feed Speed (m/min) | Shielding Gas | Welding Method | Main Application Areas |
| ER4043 (Al-Si) | 0.8 / 1.0 / 1.2 | 90 - 180 | 18 - 22 | 4.5 - 9.0 | 100% Ar | MIG / TIG | Thin aluminum sheets, automotive, electronics |
| ER5356 (Al-Mg) | 0.8 / 1.0 / 1.2 | 100 - 200 | 19 - 23 | 5.0 - 9.5 | 100% Ar or Ar+He mix | MIG / TIG | Marine equipment, corrosion-resistant structures |
| ER5183 (Al-Mg) | 1.0 / 1.2 / 1.6 | 150 - 280 | 20 - 24 | 6.5 - 12.0 | 100% Ar or Ar+He mix | MIG / TIG | Shipbuilding, high-strength structures |
| ER5556 (Al-Mg) | 1.0 / 1.2 | 120 - 220 | 19 - 23 | 5.5 - 10.0 | 100% Ar | MIG / TIG | Thick plate welding, pressure vessels |
| ER1100 (Al-99.0%) | 0.8 / 1.0 | 70 - 140 | 17 - 21 | 3.5 - 7.5 | 100% Ar | MIG / TIG | General purpose aluminum welding |
| Shielding Gas and Arc Transfer Modes Table | ||
| Shielding Gas Type | Arc Transfer Mode | Description |
| 100% Ar | Pulsed Spray Transfer | Good weld appearance, suitable for thin plate welding |
| Ar + 25% He | Spray Transfer | High heat input, suitable for thick plate and high-strength welding |
| Ar + 5-10% CO₂ | Globular Transfer | Stable droplet transfer, high welding efficiency, wide applicability |
| Packaging Specifications and Certifications Table | |
| Packaging Specifications | Various options: 5 kg / 15 kg / 20 kg, etc. |
| Product Standards | AWS A5.10 — American standard for aluminum alloy welding wire (ER series grades) |
| ISO 18273 — International standard for aluminum welding filler materials (AlSi, AlMg naming) | |
| GB/T 10858 — Chinese standard for aluminum and aluminum alloy welding wire | |
| Documentation Support | COA, MSDS, ROHS, REACH, CE and other document support |
| Customization Capability | Alloy composition adjustment and packaging customization available |
| Chalco aluminum welding wire products implementation standards | |
| AWS A5.10 | American standard aluminum alloy welding wire standard (ER series grade) |
| ISO 18273 | International aluminum welding filler material standards (naming methods such as AlSi, AlMg, etc.) |
| GB/T 10858 | China Aluminum and Aluminum Alloy Welding Wire Standards |
| Can provide: COA, MSDS, ROHS, REACH, CE and other document support. | |
Welding methods and aluminum welding wire selection guide
In aluminum welding projects, different welding methods have different requirements for the selection and use of welding wire alloys. Chalco provides a variety of aluminum welding wire products suitable for MIG manual welding, automated robot welding, and special flux-cored welding systems, and provides customized alloy development and technical guidance. The following is the matching relationship between common welding methods and recommended welding wire alloys:
| Welding method | Recommended welding wire type | Alloy Recommendation | Applicable instructions |
| MIG welding | Aluminum solid wire (MIG Solid Wire) | 4043, 5356, 4943 | Mainstream configuration for conventional industrial applications, suitable for welding 6 series and 5 series aluminum alloys |
| Automated MIG welding | High-precision solid welding wire (Robotic Grade Wire) | 4043, 4943, 5183 | It has higher requirements on welding wire consistency and is suitable for batch welding and welding robots. |
| Flux core MIG welding | Flux-Cored Aluminum Wire | Special composite alloys (such as customized 4045 base) | A small amount of welding is used in a gas-free environment or in special locations. It is not a mainstream product. |
| TIG automatic wire feeding system | Precision controlled wire feeding aluminum welding wire (for TIG automatic system) | 4043, 5356 | Suitable for automatic TIG process, coiled aluminum wire can be used when there is a special control system |
| SMAW manual welding | Non-wire products → Use aluminum welding rod/Stick Electrode | E4043, E5356, etc. |
Tips:
- If you are welding structural aluminum such as 6061/6063 → 4043 or 4943 is recommended
- If you are welding marine grade aluminum plates such as 5083/5052 → 5356 or 5183 is recommended
Chalco's technical team can provide one-to-one alloy recommendation services and welding process support based on your base metal composition, welding equipment and process requirements. Quick Quote
Chalco aluminum welding wire application industry and cooperation field
Chalco aluminum welding wire is widely used in many high-precision and high-strength welding industries, covering transportation, energy equipment, structural manufacturing, precision electronics and other fields. With high-quality alloy ratio, stable dimensional control and large-scale supply capabilities, we have provided welding wire materials and supporting technical services to many global customers.
Automobile manufacturing: used for MIG process scenarios such as body structure welding, battery trays, aluminum wheels, cooling modules, etc., compatible with manual and automatic welding lines.
Rail transit: Applied to the welding of high-strength aluminum structures such as the main frame of the vehicle body, supporting structure, chassis connectors, etc., meeting the requirements of lightweight and durability.
Shipbuilding and offshore equipment: welding of hulls, bulkheads, decks and aluminum alloy truss structures, using highly corrosion-resistant welding wire alloys such as 5183/5356.
Building and industrial structures: Applied to various structural parts such as aluminum brackets, railings, curtain wall systems, casings, etc., taking into account both appearance and structural performance.
New energy and energy storage systems: such as electric vehicle battery boxes, battery trays, heat exchangers, electric drive modules and other MIG automatic welding structures.
General industrial equipment manufacturing: Suitable for aluminum welding and repair operations such as conveying systems, mechanical frames, and equipment connection systems.
Chalco aluminum welding wire—your trusted welding material supplier
Chalco has a complete welding wire manufacturing system. From aluminum ingot melting and casting, alloy proportioning, aluminum rod continuous casting and rolling to aluminum wire drawing, welding wire finishing, winding and packaging, all production links can be closed-loop controlled internally to ensure product performance consistency and batch quality stability.
Aluminum welding wire is essentially a deep processing form of high-precision aluminum wire. Chalco can achieve precision wire drawing from 9.5mm aluminum rod to welding wire below 0.8mm. With online wire drawing lubrication control, surface degreasing and deoxidation process and anti-knot layer winding technology, the welding wire has excellent wire feeding stability and welding consistency in both MIG manual welding and automated welding systems.
Chalco aluminum welding wire core manufacturing capabilities
Chalco has an integrated manufacturing system from aluminum ingot smelting, alloy casting and rolling, welding wire drawing to reel packaging, ensuring that each batch of welding wire products has stable performance, controllable precision and efficient delivery, meeting the high standards of MIG welding for consistency and batch continuity.
Aluminum ingot smelting and alloy casting and rolling: Supports customized proportions of conventional and high-strength aluminum alloys, in line with international welding wire standards such as AWS/ISO.
High-precision wire drawing equipment and wire diameter control: wire diameter deviation ≤ ±0.02mm, supports large winding wire and automatic welding, and wire feeding is smooth and stable.
Surface lubrication and cleanliness control: avoid wire blockage and wire knotting problems, compatible with manipulator and robot automatic welding system.
A variety of packaging solutions: 0.5kg~250kg full range of specifications, support plastic shaft, steel shaft, barrel and other customized reels.
Welding wire quality testing and certification support: We can provide a full set of technical and regulatory compliance information such as COA, MSDS, RoHS, REACH, etc.
Core advantages of Aluminum welding wire products
As a one-stop welding material solution provider, Chalco not only provides welding wire products, but also provides full-process support from material selection to welding implementation for customer projects, helping customers maximize welding efficiency and improve structural reliability.
Material consistency control: The entire process is traceable, the alloy composition is uniform, and the weld strength and corrosion resistance are stable.
Leading wire diameter accuracy: Improves wire feeding smoothness and ensures welding automation and high-strength welding consistency.
Tightly wound to prevent tangling: suitable for high-speed welding scenarios and adapted to continuous operation of industrial robots.
Strong packaging flexibility: adapt to various process and equipment requirements, support rapid testing, small batch proofing, and large batch export.
Diverse alloy selection and development capabilities: In addition to 4043 and 5356 series, we support high-strength customization such as 4943, 5183, and 5556 to meet the needs of special industries.
Global customer coverage: support export filing, fast customs clearance, and support global project delivery.
We not only provide high-quality aluminum welding wire, but also are committed to creating a one-stop welding project solution for you, including aluminum welding wire (Welding Wire), aluminum filler rod (Filler Rod), aluminum welding rod (Stick Welding Rod) and welding technical support, to comprehensively improve your welding efficiency, structural reliability and engineering delivery guarantee.
Aluminum welding wire purchasing suggestions and FAQs
What is the difference between welding wire, welding rod and filler rod? Can they be used interchangeably?
Among aluminum welding materials, welding wire, welding rod and filler rod have similar appearances, but their uses, structures and processes are completely different and cannot be directly interchanged:
| Name | Whether it comes with a medicated skin | How to use | Is it conductive? | Typical Applications |
| Welding Wire | ❌No drug skin | Automatic wire feeding system (MIG/TIG) | ✅ | Industrial structure welding, high efficiency and continuous operation |
| Stick Welding Rod | ✅With medicated skin | Manual Metal Arc Welding (SMAW) | ✅ | Maintenance/field construction, where gas is not available |
| Filler Rod | ❌No drug skin | Manual wire feeding for TIG welding | ❌ | Precision welding, thin plates, small parts butt joint |
For other brazing welding product needs, please click [Aluminum filler rod][Aluminum brazing material] to view product details
Which welding wire alloy is suitable for welding 6061 aluminum alloy?
Commonly recommended are ER4043 (AlSi5) or upgraded version 4943. If higher strength requirements are required or heat treatment is required after welding, 4943 is recommended.
Which welding wire should I choose when welding 5083 or 5052?
ER5356 is recommended; if the structure is subject to heavy loads or is in a marine/highly corrosive environment, ER5183 or ER5556 may be selected.
How to choose welding wire diameter?
Usually selected according to the thickness of the parent material:
- <3mm: Use 0.8mm or 1.0mm
- 3–6mm: Use 1.2mm
- 6mm or thick plate welding: When using 1.6mm automatic welding/robot welding, it is recommended to use precision-wound large-diameter stable welding wire.
What wire packaging specifications does Chalco support?
Support 0.5kg / 1kg / 2kg / 5kg / 7kg / 15kg / 20kg / 250kg barrels. The reels can be made of plastic shaft, steel shaft or customized core.
Can you provide technical documents such as COA, MSDS, ROHS, etc.?
Yes. All welding wire products can be shipped with:
- COA (Composition Analysis)
- MSDS (Safety Data Sheet)
- RoHS/REACH (Environmental Compliance)
- Third-party test report (on demand)
Which wire feeders are compatible with Chalco aluminum welding wire?
- Universal MIG welding wire feeding system (Lincoln, Fronius, ESAB, OTC, etc.)
- Automated welding workstation, robotic welding arm
- TIG welding machine with wire feed module
Can you customize special alloys or wire specifications?
Of course. Chalco provides customized alloy development services, including composition fine-tuning, special ratios, composite structures, and non-standard wire diameter customization, supporting sample verification and batch supply.
If you have further questions about alloy matching, equipment adaptation or welding process, please contact our technical team and we will provide you with quick response and material recommendations.
Chalco can provide you the most comprehensive inventory of aluminum products and can also supply you customized products. Precise quotation will be provided within 24 hours.
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