Aluminum arc welding electrodes are consumables used in shielded metal arc welding (SMAW). This page covers E1100, E3003, and E4043 aluminum electrodes, including their dimensions, chemical composition, mechanical properties, and typical base metal applications. Unlike aluminum MIG and TIG welding wires, these electrodes are designed for manual arc welding with a coated electrode.
Specification of aluminum electrodes
| Electrode diameter/mm | Length of electrode/mm | ||
| Basic dimensions | Tolerances | Basic dimensions | Tolerances |
| 2.5 | ±0.05 | 340-360 | ±2.0 |
| 3.2 | |||
| 4.0 | |||
| 5.0 | ±0.07 | ||
| 6.0 | |||
Electrode grade, diameter, and length are important factors when specifying welding consumables. Chalco's aluminum welding and brazing materials range also covers other joining consumables for different processes and purchasing requirements.
Length of electrode holder end
| Electrode diameter/mm | Length of electrode holder end/mm |
| ≤4.0 | 10-30 |
| ≤5.0 | 15-35 |
Chemical composition of aluminum electrode
| Model | Si | Fe | CU | Mn | Mg | Zn | Ti | Be | Others | Al | |
| single | total | ||||||||||
| E1100 | 0.95 | 0.05-0.20 | 0.05 | - | 1.0 | - | 0.0005 | 0.05 | 0.15 | ≥99.00 | |
| E3003 | 0.6 | 0.7 | 1.0-1.5 | the rest part | |||||||
| E4043 | 4.5-6.0 | 0.8 | 0.30 | 0.05 | 0.05 | 0.20 | |||||
Tensile strength of aluminum welding electrode
| Model | Tensile strength /Mpa |
| E1100 | ≥80 |
| E3003 | ≥95 |
| E4043 |
Eccentricity of aluminum electrode
| Diameter | Eccentricity |
| ≤ 2.5 mm | ≤7% |
| 3. 2 mm and 4. 0 mm | ≤5% |
| ≥5. 0 mm | ≤4%. |
Physical properties of aluminum electrode
| Coating properties | Alkaline |
| Current range | 120-200A |
| Welding current | 120-200A |
| Melting point | 600℃ |
| Hardness (HRC) | 10 |
Characteristics and applications of three types of aluminum electrode
E1100 aluminum electrode
High plasticity and good conductivity in the weld metal.
Used for welding pure aluminum, including 1100 pure aluminum and other industrial-grade pure aluminum and aluminum alloys.
E3003 aluminum electrode
High plasticity in the weld metal.
Used for welding pure aluminum, including 1100 pure aluminum and 3003 aluminum alloy.
E4043 aluminum electrode
Contains approximately 5% silicon by weight, providing excellent fluidity at welding temperatures, making it advantageous for general-purpose welding.
Suitable for welding 6xxx series aluminum alloys, 5xxx series aluminum alloys (with magnesium content below 2.5%), aluminum-silicon casting alloys, as well as 1100 pure aluminum and 3003 aluminum alloy. The weld metal exhibits good plasticity.
