How to Weld 1100 Series Aluminum?


Introduction to 1100 Series Aluminum

Aluminum Alloy of 1100 Series belongs to pure aluminum having very good ductility, moderate strength, general purpose alloy. 1100 alloy offers high corrosion resistance, good ductility compare to other grades and high reflective finish, and off course economical too compare to other alloyed aluminum grades such as 4XXX, 5XXX or 6XXX series. The alloy is having good forming properties making it ideal for forming works jobs.

1100 series is not heat treatable type aluminum alloy. The density of this material is 2.71 gm/cm3 and melting temperature is 643 – 657°C.

Material Specification

AMS: 4001
ASTM: B 209

SAE AMS QQ: A-250/1

Chemical and mechanical properties

Chemical properties of Al 1100

Weight%AluminumCopperSilicon + IronManganeseZincOthers
1100Remainders0,05 – 0,0200,95 max0,05 max0,10 max0,05 (each)
0,15 (total)

Welding of 1100 Series Aluminum

The welding of Aluminum 1100 alloy can be carried out using:

  1. ER4043
  2. ER1100

The below table shows the filler wire types for various aluminum grades including 1100 series. ER4043 shall be used when need maximum strength for 1100 alloy welding. ER1100 shall be used for welding alloy 1100 aluminum when maximum ductility, salt water corrosion resistance and color match after anodizing is required.

Preheat and interpass during welding

Maximum preheat and interpass temperature of 120ºC shall be used for aluminum welding of Alloy 1100, 3XXX, 4XXX, 5XXX series.

Click here to read Full Aluminum Welding guide.

Shielding/ Purging/ Backing gas for Aluminum welding

Pure Argon is widely used. Argon-Helium mixture in MIG welding. Helium addition helps for a better weld formation and increases the welding speed. Helium also minimizes the risk of pores and lack of fusion. Pure helium is not used due to the high Ionisation potential of the gas as well as the high cost of the gas.

Welding parameters for TIG/ MIG welding of Al1100

Selection of welding parameters for aluminium welding depends on wire diameter and material thickness. When welding with 0.030 inch wire dia, ampere range of 100-130 amp is used for thickness upto 0.125 inches for aluminum material. Refer below table for detailed welding parameters such as current, voltage, wire feed speed and shielding gas flow rate.

Microstructure of Al1100 material

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