ER1100 Welding Wire
COREWELD 1100 is the commercially pure aluminium filler metal from Metracore Alloys Private Limited, supplied as ER1100 welding wire for TIG and MIG work on 1xxx series aluminium. Welders select it when a joint demands corrosion resistance and conductivity. The alloy holds a minimum of 99.00% aluminium and melts close to the base metal it joins, which keeps dilution predictable on thin sections. Fabricators apply ER1100 welding wire to tank shells, heat exchanger repairs, busbar connections and general sheet work.
COREWELD 1100 Product Datasheet
Our datasheet sets out the AWS classification, chemical limits, available diameters, rod lengths and packaging weights in a single reference document. Check it against your WPS before you raise an enquiry.
Understanding ER1100 Welding Wire
AWS A5.10 classifies ER1100 as a commercially pure aluminium filler, with copper between 0.05% and 0.20% as the only deliberate addition. Silicon plus iron stays below 0.95%. Because the alloy carries almost no alloying load, weld metal deposited from ER1100 welding wire keeps the electrical and thermal conductivity and the chemical resistance of the parent 1xxx material, and it anodises to a close colour match. Strength stays low by design. Filler selection never rests on the alloy alone: match the base metal grade, the joint restraint, the service temperature and the post-weld finish, then confirm the diameter and form, whether you need an ER1100 TIG rod or spooled wire.
Technical Specifications of COREWELD 1100
Buyers quoting ER1100 welding wire need four details before a price can be fixed: diameter, product form, length or spool weight, and the certification required. The table below summarises the product. Confirm every figure against the official COREWELD 1100 datasheet, since diameters and packaging change with production lot and supply region.
Brand
COREWELD 1100
Product Name
ER1100 Welding Wire
AWS Classification
ER1100
Material Type
Aluminium Filler Metal (99.00% Al min)
Welding Processes
TIG (GTAW) / MIG (GMAW), subject to product form
Applicable Standard
AWS A5.10 / ASME SFA-5.10, subject to certification
Available Wire Diameters
0.8 mm, 1.0 mm, 1.2 mm, 1.6 mm (MIG spools); 1.6 mm, 2.0 mm, 2.4 mm, 3.2 mm, 4.0 mm (TIG rods), to be confirmed
Rod Lengths
1000 mm standard; confirm against datasheet
Packaging
2.5 kg and 5 kg rod tubes or cartons; 0.5 kg, 2 kg and 6 kg MIG spools, to be confirmed
Base Material Compatibility
1050, 1060, 1070, 1080, 1100, 1200, 1350 and similar 1xxx grades
Reach out to Metracore Alloys Private Limited for reliable ER1100 Welding Wire Solutions
Chemical Composition and Mechanical Properties of ER1100
Composition drives everything the weld does after it cools. Copper at 0.05% to 0.20% gives ER1100 a small hardness gain over refined aluminium without pulling down conductivity, while the combined silicon and iron ceiling of 0.95% controls intermetallic formation. Beryllium stays at 0.0003% maximum for operator safety. Mechanical values deserve more caution than composition values. AWS A5.10 does not publish minimum tensile or yield figures for ER1100 deposits in the way steel filler specifications do, so any number you read describes a test weld, not a guarantee on your joint.
Chemical Composition of ER1100
Limits below follow AWS A5.10 for the ER1100 classification.
| Element | Composition |
| Aluminium (Al) | 99.00% min |
| Silicon (Si) + Iron (Fe) | 0.95% max combined |
| Copper (Cu) | 0.05% to 0.20% |
| Manganese (Mn) | 0.05% max |
| Magnesium (Mg) | Not individually specified; covered under others, 0.05% each max |
| Zinc (Zn) | 0.10% max |
Mechanical Properties of ER1100 Weld Metal
Figures represent typical as-welded transverse test results on 1xxx base material.
| Property | Value |
| Tensile Strength | Approx. 90 MPa (13 ksi), as welded |
| Yield Strength | Not specified in AWS A5.10; approx. 35 to 45 MPa typical |
| Elongation | 25% to 35% typical |
| Hardness | Approx. 23 to 30 HB typical |
Welding process, joint design, heat input, and test method all shift these results. Never read them as base metal or product properties.
ER1100 TIG Rod vs. ER1100 MIG Wire
Form separates the two. An ER1100 TIG rod arrives as a straight cut length, usually 1000 mm, and the welder feeds it into the arc by hand while controlling current through a foot pedal or torch switch. Control is high; deposition is slow. ER1100 MIG wire comes layer wound on a spool and feeds continuously through the gun at a set rate, which suits longer runs and thicker sections but demands a U groove drive roll, a PTFE or graphite liner and a push pull or spool gun to stop the soft aluminium birdnesting. Choose the ER1100 TIG rod for thin gauge sheet, pipe root passes and repair work. Choose spooled wire for production fillets.
ER1100 TIG Rod Applications
An ER1100 TIG rod earns its place wherever the joint has to conduct, resist chemical attack or anodise to match the parent sheet, rather than carry structural load. Fabricators use it across these applications.
- Chemical storage tanks and process vessels
- Heat exchanger tube and header repair
- Food handling equipment and dairy plant fabrication
- Electrical busbars and conductor connections
- HVAC ducting and thin gauge sheet assemblies
- Architectural trim requiring anodised colour match
- Nameplates, enclosures and light fabricated housings
- Rebuild of worn 1xxx aluminium components
Manufacturing Process of ER1100 TIG Rod
- Cast 1100 alloy billet by the direct chill route, then homogenise
- Scalp the billet surface and hot extrude to redraw rod stock
- Cold draw through successive dies to the target diameter
- Anneal between draw passes to restore ductility
- Clean and degrease to strip drawing lubricant and oxide
- Straighten, then cut to 1000 mm lengths for ER1100 TIG rod production
- Layer wind onto spools where MIG supply applies
- Verify chemistry by spectrometer and check diameter tolerance
- Pack in sealed tubes or cartons to block moisture pickup
Key Benefits of COREWELD 1100 Aluminium Filler Metal
- ER1100 welding wire deposits weld metal that matches 1xxx base alloys in composition, so the joint retains the corrosion behaviour of the parent material.
- High electrical and thermal conductivity makes the alloy workable for busbar and heat transfer joints where resistance matters.
- The deposit anodises to a light, near white finish, which helps on architectural and decorative work.
- Soft, formable weld metal tolerates post-weld bending and dressing without cracking at the toe.
- An ER1100 TIG rod gives precise control on thin sheet, where excess heat burns through.
- The low melting range reduces the energy needed to establish the pool on light gauge aluminium.
Why Choose COREWELD 1100 ER1100 Welding Wire?
COREWELD 1100 carries the ER1100 classification under AWS A5.10, with chemistry held within the published limits and verified by lot analysis. We document diameter tolerance, rod length and packaging weight for every size we supply, so your welders receive the same product on repeat orders. Our technical team reviews your base alloy and joint configuration before confirming a size. Buyers comparing ER1100 welding wire against 4043 or 5356 should weigh conductivity and colour match against strength, since ER1100 deposits sit well below both. Read the datasheet first, then confirm the ER1100 TIG rod diameter that matches your sheet thickness.
ER1100 Welding Wire Supply and Technical Support
Metracore Alloys supplies ER1100 welding wire as spooled MIG wire and as cut length TIG rod, with diameters and packaging confirmed per order. Bulk enquiries for repeat production receive a dedicated quotation. Send us your base alloy grade, plate or sheet thickness, welding process, required diameter and the certification you need, and our team will confirm the matching product form. We also advise on ER1100 TIG rod sizing where joint access limits rod movement.
Request a quotation with your base alloy grade and required wire diameter.
Frequently Asked Questions About ER1100 Welding Wire
What is ER1100 welding wire used for?
Welders join commercially pure aluminium grades such as 1050, 1060, 1100 and 1350 with it. Typical work covers chemical tanks, heat exchangers, busbars, food equipment and thin gauge sheet fabrication.
What is the difference between ER1100 TIG rod and ER1100 MIG wire?
Form and feeding separate them. An ER1100 TIG rod is a 1000 mm cut length fed by hand, while ER1100 MIG wire feeds continuously from a spool through the gun at a preset rate.
Which aluminium alloys can be welded using ER1100 filler metal?
Use it on 1xxx series grades including 1050, 1060, 1070, 1080, 1100, 1200 and 1350. It also suits 3003 in some joints. Confirm compatibility against your WPS.
What sizes are available for COREWELD 1100 welding wire?
Rods run 1.6 mm to 4.0 mm in 1000 mm lengths; spooled wire runs 0.8 mm to 1.6 mm. Check the datasheet, since stocked diameters vary by lot.
Which standard applies to ER1100 welding wire?
AWS A5.10 governs the classification, with ASME SFA-5.10 as the equivalent code reference. Certification to either depends on the lot and the test documentation you request at order stage.
Products
Exporter, Manufacturer & Supplier of ER1100 Welding Wire in various material and sizes.