Aluminum solid wire is used in two different weld processes. Gas Metal Arc Welding (GMAW or MIG) and Gas Tungsten Arc Welding (GTAW or TIG). Aluminum wire is available in a wide variety of diameters from .023-.093. It is also available in spooled wire and cut lengths. Aluminum wire is typically used for the joining of two pieces of aluminum in the electric welding application. The wire is smooth and drawn down to the appropriate diameter

Aluminum wire is available in a variety of chemical metallurgies. The different chemical make-up not only determines the different weldability of the wire, but also the tensile strength of the finished product. An Argon or Argon/Helium mix shielding gas is often used as a fluxing agent to prevent atmosphere from getting into the weld puddle before it hardens.

In selecting the proper Aluminum wire for a particular job, it is important to consider the parent metal, the strength of the weld needed, the finished appearance of the weld and the required resistance to oxidation. Aluminum wires are typically available in the following classifications based on the its chemical composition: 110, 4043, 5184, 5356 and 5654. The determining factor in choosing a specific classification are: Parent material, crack resistance, tensile strength, weld conductivity, service temperature, corrosion resistance and color match.

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