16 Types of Aluminium Welding Wire Explained
Aluminium welding wire falls into four working families: pure aluminium (1xxx), aluminium-manganese (3xxx), aluminium-silicon (4xxx) and aluminium-magnesium (5xxx). Four grades, 4043, 5356, 5183 and 5554, cover most fabrication; the others serve conductors, chemical plant, brazing or specific national standards. This guide compares 16 wires that buyers ask about, gives their chemistry and explains how to pick the right one for the base metal and service.
- Families
- 1xxx · 3xxx · 4xxx · 5xxx
- Workhorse grades
- 4043 · 5356 · 5183 · 5554
- Standards
- AWS A5.10 · ISO 18273
- Forms
- MIG spools, TIG rods, drums
How aluminium filler wires are classified
Filler metals are classified by AWS A5.10 in North America (ER for wire usable as electrode or rod, R for rod only) and by ISO 18273 internationally (S Al followed by the alloy number and chemical symbol, for example S Al 5356 / AlMg5Cr(A)). National standards such as GB/T 10858 and GOST 7871 add their own grades. The alloy numbers follow the wrought-alloy system, so the first digit tells you the main alloying element.
Choosing a filler means balancing five things: crack resistance during solidification, strength of the joint, corrosion resistance, colour match after anodising and service temperature. Silicon fillers flow well and resist hot cracking; magnesium fillers give stronger, more ductile welds that anodise to a closer colour match. No single wire wins every category, which is why the selection chart below matters more than any list of grades.
Pure aluminium wires: 1100, 1060 and 1070
Pure aluminium fillers are used to weld 1xxx base metals where conductivity or corrosion resistance in chemical and food service matters more than strength.
| Grade | Key chemistry (%) | Typical use |
|---|---|---|
| 1. ER1100 / S Al 1100 | Al ≥ 99.00; Cu 0.05 – 0.20; Si + Fe ≤ 0.95 | General welding of 1060, 1100 and 3003 where strength is low priority; good anodised colour match |
| 2. 1060-type wire | Al ≥ 99.60; Si ≤ 0.25; Fe ≤ 0.35 | Busbar, smelter and chemical-plant welds needing higher conductivity |
| 3. S Al 1070 | Al ≥ 99.70; Si ≤ 0.20; Fe ≤ 0.25 | High-purity busbar and electrolytic equipment |
ER1188 (99.88 % Al) is the AWS grade for highest-purity work. 1060 wire is a national-standard and trade grade rather than an AWS classification.
Aluminium-manganese wires: 3003, 3103 and 3A21
| Grade | Key chemistry (%) | Typical use |
|---|---|---|
| 4. 3003-type wire | Mn 1.0 – 1.5; Cu 0.05 – 0.20 | Matching welds on 3003 tanks, ducts and heat-exchanger parts |
| 5. S Al 3103 | Mn 0.9 – 1.5; Mg ≤ 0.30 | ISO grade for Al-Mn sheet and tube assemblies |
| 6. 3A21-type wire (SAl3A21) | Mn 1.0 – 1.6 | National-standard grade for Al-Mn fuel and oil lines, containers |
Manganese wires give welds slightly stronger than pure aluminium with similar corrosion resistance. In most fabrication shops, 4043 or 1100 is used on 3003 instead, because Al-Mn wire is less widely stocked.
Aluminium-silicon wires: 4043 and 4047
| Grade | Key chemistry (%) | Typical use |
|---|---|---|
| 7. ER4043 / S Al 4043 | Si 4.5 – 6.0 | The general-purpose filler for 6xxx alloys and castings; best hot-crack resistance on 6061 and 6063; suits parts that are heat-treated after welding |
| 8. ER4047 / S Al 4047 | Si 11.0 – 13.0 | Lower melting point and very fluid; leak-tight welds on radiators and heat exchangers, castings, and as a brazing filler |
4043 welds turn dark grey when anodised and have lower ductility than 5xxx welds. Do not use silicon fillers on 5xxx alloys with more than about 2.5 % Mg: brittle Mg₂Si forms in the weld. Newer grades 4943 and 4643 add magnesium for higher as-welded or heat-treated strength.
Aluminium-magnesium wires: 5356, 5183, 5554, 5087, 5A06, 5B06
| Grade | Key chemistry (%) | Typical use |
|---|---|---|
| 9. ER5356 / S Al 5356 | Mg 4.5 – 5.5; Mn 0.05 – 0.20; Cr 0.05 – 0.20; Ti 0.06 – 0.20 | Most widely used filler; 5xxx and 6xxx structures, boats, trailers; good anodised colour match |
| 10. ER5183 / S Al 5183 | Mg 4.3 – 5.2; Mn 0.50 – 1.0; Cr 0.05 – 0.25 | Highest strength for 5083 and 5456; ships, tankers, cryogenic tanks |
| 11. ER5554 / S Al 5554 | Mg 2.4 – 3.0; Mn 0.50 – 1.0; Cr 0.05 – 0.20 | For 5454 and parts in service above 65 °C, such as tankers carrying hot cargo |
| 12. S Al 5087 | Mg 4.5 – 5.2; Mn 0.7 – 1.1; Zr 0.10 – 0.20 | Zirconium refines the weld grain and cuts hot cracking; rail vehicles and shipbuilding |
| 13. SAl5A06 | Mg 5.8 – 6.8; Mn 0.5 – 0.8; Ti 0.02 – 0.10 | National-standard filler for АМг6 / 5A06-type high-Mg alloys |
| 14. SAl5B06 | Mg 5.8 – 6.8; Mn 0.5 – 0.8; Ti 0.10 – 0.30 | As 5A06 with more titanium for finer weld grain |
Fillers with more than 3 % magnesium should not be used for parts held above about 65 °C, because β-phase can form along grain boundaries and make the weld susceptible to stress-corrosion cracking. That is the reason ER5554 exists. ER5556 (Mg 4.7 – 5.5) is a further high-strength option close to 5183.
6061 and 7075 wire: why they are not normal fillers
| Grade | Key chemistry (%) | What to know |
|---|---|---|
| 15. 6061 wire | Mg 0.8 – 1.2; Si 0.40 – 0.80; Cu 0.15 – 0.40 | Not an AWS filler. Welding 6061 with matching filler gives a crack-sensitive weld; use 4043 or 5356. 6061 wire is mainly for fasteners and special colour-match trials. |
| 16. 7075 wire | Zn 5.1 – 6.1; Mg 2.1 – 2.9; Cu 1.2 – 2.0 | Not weldable by fusion. 7075 wire is a rivet, fastener and cold-heading material, not a welding consumable. Weldable 7xxx alloys such as 7005 and 7020 are joined with 5356 or 5183. |
Filler selection chart by base metal
| Base metal | First choice | Alternative | Reason |
|---|---|---|---|
| 1060, 1100, 1350 | ER1100 / 1070 | ER4043 | Conductivity and corrosion vs ease of welding |
| 3003 | ER1100 or ER4043 | ER5356 | Easy welding; 5356 for more strength |
| 5052 | ER5356 | ER5554 (hot service), ER4043 | Strength and colour match |
| 5083, 5456 | ER5183 | ER5556, ER5356 | Highest strength |
| 5454 | ER5554 | ER5356 (below 65 °C) | Elevated-temperature service |
| 6061, 6063, 6082 | ER4043 | ER5356 | 4043 for crack resistance and PWHT; 5356 for strength and anodising |
| 7005, 7020 | ER5356 | ER5183 | Crack resistance and strength |
| A356 and Al-Si castings | ER4043 | ER4047 | Silicon matching |
| 2219 | ER2319 | ER4043 | Heat-treatable welded structures |
General guidance from published AWS and producer charts. Qualify the procedure to the applicable code (e.g. AWS D1.2, ISO 15614-2) for production work.
Forms, sizes and storage
Typical supply
- MIG wire
- 0.8, 0.9, 1.0, 1.2 and 1.6 mm on spools from about 0.5 kg upward, and drums for robotic lines
- TIG rod
- 1.6, 2.0, 2.4, 3.2, 4.0 and 5.0 mm, usually in 1 m (36 in) lengths
- Certification
- Certificate of conformity or test report to AWS A5.10 / ISO 18273, with chemistry per lot
- Store wire sealed and dry; moisture and hydrated oxide on the wire cause weld porosity
- Return part-used spools to their bag or a heated cabinet
- Use push-type or push-pull feeders with U-groove rolls and plastic liners for soft wire
- Use AC TIG or DC pulsed MIG with argon or argon-helium shielding gas
References and standards
- AWS A5.10/A5.10M – Welding Consumables: Wire Electrodes, Wires and Rods for Welding of Aluminum and Aluminum-Alloys
- ISO 18273 – Welding consumables: wire electrodes, wires and rods for welding of aluminium and aluminium alloys. Classification
- AWS D1.2/D1.2M – Structural Welding Code: Aluminum
- ISO 15614-2 – Welding procedure test for arc welding of aluminium and its alloys
- The Aluminum Association – Welding Aluminum: Theory and Practice
Aluminium (aluminum) welding wire: frequently asked questions
Which aluminium welding wire is most common?
ER5356 and ER4043 together cover most fabrication. 5356 is used for 5xxx and many 6xxx structures; 4043 for 6xxx alloys, castings and parts heat-treated after welding.
Should I use 4043 or 5356 on 6061?
4043 for best crack resistance, smoother beads and post-weld heat treatment; 5356 for higher shear strength, more ductility and a better colour match after anodising.
What filler is used for 5083 marine plate?
ER5183, which gives the highest as-welded strength on 5083 and 5456. ER5356 is acceptable for lower-strength requirements.
Why not use 5356 above 65 °C?
Fillers with more than 3 % Mg can become sensitised in prolonged warm service and suffer stress-corrosion cracking. Use ER5554 instead.
Can 7075 be welded with 7075 wire?
No. 7075 cracks badly in fusion welding and is normally riveted or bolted. Weldable 7xxx alloys such as 7020 use 5356 or 5183.
Do you supply MIG spools and TIG rods?
Yes. Metline supplies aluminium MIG wire and TIG rods in the common grades and diameters, with certificates, shipped worldwide.
Choosing a filler wire?
Send the base alloys, process, diameter and quantity. We will recommend a grade and quote with certificates.
