Aluminum stick welding rods are commonly used in SMAW (Shielded Metal Arc Welding), one of the most practical welding methods for structural repair, outdoor work, and emergency patch welding. Their structure consists of a conductive aluminum core wire and a flux coating. During welding, the aluminum core conducts electricity and melts to form the weld, while the flux decomposes at high temperature to release protective gases and slag, creating a self-shielded environment.
Chalco does not supply finished flux-coated electrodes, but instead provides the core metal part—high-precision aluminum alloy electrode core wires. These feature excellent conductivity, chemical consistency, and processing stability, and are widely used for the manufacture of E4043, E5356 and other aluminum stick electrodes. For finished flux-coated electrodes, please consult Chalco's sales team.
Technical Specifications of Chalco Aluminum Stick Welding Rod Cores
Core Diameter (inch): Standard: 1/16" (1.6 mm), 3/32" (2.4 mm); customizable 1.2–3.5 mm
Length: Fixed lengths available: 300 mm, 350 mm, 400 mm, 500 mm (or per customer request)
Surface Condition: Drawn, bright finish, or roughened (to enhance flux adhesion)
Tolerance: Within ±0.02 mm, ensuring stable feeding and high electrical consistency
Material Alloys: 4043, 5356, 5183 common stick electrode core alloys
Standards: Chemistry complies with AWS A5.10 / ISO 18273 ER/E series (bare, uncoated condition)
Chalco Hot-Selling Electrode Core Alloy Types
Below are Chalco's long-term supply grades suitable for stick welding electrode manufacturing, featuring stable conductivity, chemical composition, and processing adaptability. Standard diameters such as 1/16" and 3/32" are available.
4043 Aluminum Core Wire (AlSi5)
Features: 5% Si, low melting point, good fluidity, low spatter, reduced hot cracking.
Applications: Widely used for welding 6xxx aluminum, castings, and medium/low-strength structural aluminum. One of the most common electrode core alloys.
Typical Electrode Code: E4043 Stick Electrode (flux to be added by the customer).
5356 Aluminum Core Wire (AlMg5)
Features: 5% Mg, high weld strength, bright weld appearance, better corrosion resistance than Si-based alloys.
Applications: Welding 5xxx aluminum alloys, common in shipbuilding and vehicle repair electrodes; excellent salt-spray resistance.
Typical Electrode Code: E5356 Stick Electrode.
5183 Aluminum Core Wire (AlMg4.5Mn)
Features: Higher strength than 5356, strong weld metal retention, suitable for high-strength and corrosion-resistant joints.
Applications: Recommended for marine engineering, oil & gas pipelines, aluminum pressure vessels, and heavy-duty repair electrodes.
Typical Electrode Code: E5183 Stick Electrode.
All core products are available in standard or customized sizes, supporting both automatic flux-coating machines and manual electrode production. Contact us for details.
Chalco Aluminum Stick Welding Rod Core Manufacturing & Customization Capabilities
Chalco has mature aluminum core rod and wire production processes to support stick welding electrode manufacturers. We can supply various diameters, lengths, and surface finishes according to flux formula requirements, electrode design, and welding machine compatibility.
- In-house continuous casting & rolling of aluminum rods, plus precision wire drawing (9.5 mm rod → fine wire core).
- Surface roughness or coating treatment adjustable per flux recipe.
- Alloy composition fine-tuning and special design support.
- Samples available, with COA composition report and MSDS documentation.
Industries Served with Chalco Electrode Core Wire
Chalco aluminum electrode cores are widely used by stick electrode manufacturers and welding consumable integrators. They support flux development, OEM electrode production, emergency repair materials, and engineering consumables. We not only provide stable raw materials, but also comprehensive support from alloy selection to process collaboration.
Electrode manufacturers: Mass production and private-label stick electrodes.
Power engineering & maintenance: Emergency repair electrodes for on-site/outdoor work.
Shipbuilding & rail transit: Structural repair and emergency welding of aluminum parts.
Defense & emergency systems: Wartime repair and quick restoration of equipment.
Welding consumable distributors / project contractors: Custom electrode materials.
Cooperation Models
- OEM Supply: Tailored size/surface/alloy core wires for specific flux production lines.
- ODM Development: Joint development of new flux systems and alloy combinations.
- Project Support: Supply of cut-to-length rods for non-standard electrodes.
- Trial & Mass Production: From R&D samples to stable bulk supply.
Knowledge Center & FAQ
What's the difference between electrode core wire, welding wire, filler rod, and finished electrodes?
| Name | Flux Coated | Process | Conductive | Notes |
| Electrode Core Wire | ❌ Bare | Used for stick electrode manufacturing | ✅ Yes | Chalco’s product |
| Welding Wire | ❌ Bare | MIG / TIG welding | ✅ Yes | Supplied as coils |
| Filler Rod | ❌ Bare | TIG manual filler | ❌ No (not an electrode) | Solid rods, non-electrical |
| Finished Welding Rod | ✅ Flux-coated | SMAW (stick) | ✅ Yes + self-shielding | Not supplied by Chalco |
Chalco supplies core wire only, not finished electrodes, and they cannot be directly used for SMAW. If you need finished coated welding electrodes, please consult our sales team.
For other welding product needs, please click [Welding Wire] [Filler Rod] to view product details.
Do you supply finished electrodes ready for manual welding?
No. Chalco only supplies electrode core wires for flux-coated electrode manufacturers. Not flux-coated, not ready-to-use.
Which electrode codes can your core wires be used for?
Our 4043, 5356, and 5183 core wires are suitable for E4043, E5356, and E5183 stick electrodes.
Do you provide samples, analysis reports, or certifications?
Yes. COA, MSDS, RoHS, and REACH documents available; samples can be supplied for testing.
What's the MOQ? Can you customize?
Small trial orders supported. Custom length, surface treatment, and alloy adjustment are available.
Are the cores compatible with AC welding machines or specific fluxes?
Core wire itself is compatible with both AC/DC; actual compatibility depends on flux design. Chalco can optimize core surface and composition to match your coating process.
Contact Chalco today for samples or tailored aluminum electrode core wire solutions.
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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