What we know is that aluminum is extremely difficult to weld.
It is a soft metal and is a sensitive subject to warping due to high heat. So one needs a steady hand and experience when welding aluminum. Some would also emphasize the usage of a good welding machine as well.
What also needs to be taken into consideration is the type of aluminum welding wire. Welding aluminum becomes much easier with the right filler, and choosing the best aluminum welding wire for the job comes down to the alloy you are joining.
General-purpose aluminum wire is not going to do the trick all the time.
So in order to help you understand which one works best, we present to you the aluminum wire needed to successfully MIG weld aluminum and also by using other types of welding processes.
Best Aluminum Welding Wire Comparison Table
| Image | Name | Diameter | Spool Weight | AWS Class | Shielding Gas | Material | Check Price |
|---|---|---|---|---|---|---|---|
| ER4043 and ER5356 Aluminum MIG WireGet 10% Off With Coupon: -10% WELDPROS | .030" / .035" | 1 lb | ER4043 / ER5356 | 100% Argon | Aluminum | Check Price |
 | Hobart ER5356 Aluminum MIG Welding Wire 0.030 in, 1 lb Spool | .030" | 1 lb | ER5356 | 100% Argon | Aluminum | Check Price |
| (Processed In USA) M-4043 ER4043 Aluminum Welding Wire | 3/64" | 15 lb | ER4043 | 100% Argon | Aluminum | Check Price |
 | Blue Demon ER5356 Aluminum MIG Wire | .035" | 1 lb | ER5356 | 100% Argon | Aluminum | Check Price |
 | HARRIS 05356F1 ER5356 Aluminum MIG Welding Wire | .035" | 1 lb | ER5356 | 100% Argon | Aluminum | Check Price |
Best Aluminum Welding Wire Review
Welding aluminum will become easier with suitable aluminum metal wire. There are a few things that you have to consider first before you start welding aluminum.
The first thing to start with is cracking susceptibility, which could occur when the weld solidifies. The next thing that comes to mind is weld strength as it is really hard to obtain weld strength as strong as the base materials. Next are the aesthetics, as you would want to get clean aluminum welds. But some filler alloys can result in sooty residue on the surface, so a good choice needs to be made before starting everything. Also, you need to match the corrosive properties of the base metal with aluminum welding as well.
Considering the temperature is an important factor also as some alloys are susceptible to cracking when exposed to a temperature over 150 degrees. Also, determining the larger diameter wire for aluminum welding is an important nat piece of the puzzle as well. Finally, deformation under stress is also an issue and one has to think long and hard before choosing the best filler for welding aluminum.
Now when we have all of that out of the way consider our review of all the useful wires used for welding this type of soft metal.
1. ER4043 and ER5356 Aluminum MIG Wire – Best Overall Aluminum MIG Wire
Best Overall Aluminum MIG Wire
ER4043 and ER5356 Aluminum MIG Wire
YesWelder sells this wire in both aluminum alloys, which is a lot more convenient than it sounds. You pick ER4043 or ER5356, .030 or .035 inch, in a one-pound spool. If your shop handles a mix of projects, you can grab the right alloy per job instead of stocking two brands. The spools are plastic four-inch rolls that drop into any standard spool gun.
Get 10% Off With Coupon: “-10% WELDPROS”
| Alloy Options: | ER4043 / ER5356 | Spool Weight: | 1 lb |
| Diameter: | .030″ / .035″ | Shielding Gas: | 100% Argon |
| Melting Range: | 1065–1175°F | Tensile Strength: | 27–38 ksi |
| Material: | Aluminum | Process: | MIG |
| Manufacturer: | YesWelder | Price: | See YesWelder |
The ER4043 option is the one I reach for on castings and 6xxx series parts. It has silicon in the mix, which makes the puddle wet out nicely and forgives a slightly dirty joint. The finished weld comes out bright and smooth with minimal spatter. Tensile runs around 27 ksi, fine for anything cosmetic or lightly loaded. Two things 4043 will not do: it turns dark after anodizing, and it does not belong near saltwater.
The ER5356 side is where the strength lives. The magnesium in the alloy pushes tensile to about 38 ksi and adds real shear strength, so it holds up on boat rails, truck boxes, and anything that lives outside. It also keeps its color through anodizing, which matters if the part gets finished rather than painted. It feeds a touch stiffer than 4043, but on a one-pound spool with a short torch lead that difference is barely noticeable.
I burn through a one-pound spool of aluminum faster than I expect every time, mostly because aluminum MIG runs hot and the wire disappears. That is why the multi-pack option exists: YesWelder sells these in one, three, and five packs, and the per-spool price drops noticeably at three. For a weekend welder, a single spool is plenty. For a shop doing regular aluminum work, the packs are the sensible way to buy.
Feed quality is what usually separates good aluminum wire from the stuff that bird-nests every third bead. These spools are wound evenly and ran clean through my spool gun with no drama once the tension was set. YesWelder also knocks 10% off with the WELDPROS coupon at checkout, which is worth grabbing on the multi-packs.
If you are new to aluminum MIG, the .035 ER4043 spool is the easiest starting point. If you are fixing trailers or anything marine, start with ER5356. Either way you get both options from one listing, and you are not committing to a ten-pound roll of one alloy that might sit on the shelf for a year.
Pros
- Both ER4043 and ER5356 from one listing, in .030″ or .035″
- Low spatter, smooth bead once settings are dialed
- Even layer winding feeds clean through a spool gun
- ER4043 wets out on castings and 6xxx parts
- ER5356 hits about 38 ksi for structural and marine work
- Three and five packs cut the per-spool price
- Extra 10% off with the WELDPROS coupon
- One-pound spool swaps quickly between alloys
Cons
- A pound of aluminum wire goes fast on a hot afternoon
- ER4043 darkens after anodizing; pick 5356 for finished parts
- Per-pound cost runs higher than a bulk 15-pound spool
2. Hobart ER5356 Aluminum MIG Welding Wire 0.030 in, 1 lb Spool – Best ER5356 for Thin Aluminum
Best ER5356 for Thin Aluminum
Hobart ER5356 Aluminum MIG Welding Wire 0.030 in, 1 lb Spool
Hobart’s ER5356 in .030-inch diameter is the wire that makes sense when the aluminum you weld is thin. The link on this page goes to the one-pound spool in that thin diameter, which is deliberate: at .030 you can weld sheet stock without chasing burn-through the whole time.
| Diameter: | .030″ | Spool Weight: | 1 lb |
| AWS Class: | ER5356 | Shielding Gas: | 100% Argon |
| Melting Range: | 1060–1175°F | Tensile Strength: | 38 ksi |
| Material: | Aluminum | Process: | MIG |
| Manufacturer: | Hobart | Price: | See Amazon |
Thin wire matters more than most people expect. A .035 wire on 16-gauge aluminum wants to punch through before the puddle forms, and you end up fighting the machine settings and the travel speed. The .030 lays a smaller, cooler bead, so gutter stock, trim, and body panels survive contact with it. You trade deposition for control, and on sheet metal that is the right trade.
It is still an ER5356 underneath, so you keep the magnesium alloy’s two big advantages: around 38 ksi tensile and saltwater corrosion resistance. Boats, trailers, dock hardware, anything that gets splashed, this wire is happy there. It also anodizes bright, unlike 4043, so finished parts keep a clean look.
Hobart winds these spools evenly, which shows up as fewer feed interruptions. Aluminum wire is soft, and a sloppy wind will bird-nest inside the gun liner. This one ran through my spool gun without any of that. It is AWS A5.10 wire and runs DCEP like every aluminum MIG setup. Nothing exotic in the settings.
One quirk worth knowing: the plastic spool flanges sometimes have a rough edge from molding that catches the wire during the first few feet. Thirty seconds with a bit of sandpaper takes care of it. It is the kind of thing Hobart could fix at the factory, but it is also the easiest prep step in welding.
If most of your aluminum work is sheet and light plate, this spool covers it. If you weld half-inch plate all day, get something in 3/64 and a bulk spool. At one pound you are also buying the chance to try ER5356 on thin stock without much money on the line.
Pros
- .030″ diameter is the right size for 16-gauge and thinner
- Cooler bead means less burn-through on sheet
- ER5356 gives you 38 ksi and saltwater resistance
- Even spool winding keeps feed interruptions down
- AWS A5.10 rated, runs DCEP with plain argon
- Small spool makes alloy switching painless
- Hobart quality control at a price that does not sting
- Welds 5xxx series base metal properly
Cons
- Spool flanges sometimes need a quick sanding
- One pound is not a production quantity
- .030 is the wrong choice for heavy plate
3. Blue Demon ER5356 Aluminum MIG Wire – Best Budget ER5356 Wire
Best Budget ER5356 Wire
Blue Demon ER5356 Aluminum MIG Wire
Blue Demon sells genuine ER5356 at one of the lowest prices around, and for a lot of hobby welders that settles it. This is the .035 version on a one-pound plastic spool. It is not the fanciest wire, and it does not pretend to be. What it does is run a solid bead for the lowest entry price.
| Diameter: | .035″ | Spool Weight: | 1 lb |
| AWS Class: | ER5356 | Shielding Gas: | 100% Argon |
| Melting Range: | 1060–1175°F | Tensile Strength: | 38 ksi |
| Material: | Aluminum | Process: | MIG |
| Manufacturer: | Blue Demon | Price: | See Amazon |
The alloy does the heavy lifting here. ER5356 means magnesium in the mix, which means about 38 ksi tensile, good shear strength, and welds that shrug off saltwater. For boat repairs, trailer frames, and anything aluminum that lives outdoors, this is the right alloy even at the budget price.
.035 is the most forgiving diameter for general work: thin enough for sheet with careful settings, thick enough for plate with more passes. The wire is qualified for all positions, so flat, vertical, and overhead all work with the same spool. That saves you from buying a second diameter when a project goes vertical.
The one thing the packaging does not tell you clearly is that this wire needs argon. Aluminum MIG is never gasless, but the label does not say it, and plenty of beginners assume any wire on a small spool works like flux-core. Buy a bottle of pure argon with this spool or the beads will look like a bird’s nest.
For the money, feed consistency is fine. I have had spools with a slightly rougher finish on the flange, same as pricier brands. A quick sand fixes it. The weld itself comes out clean once the machine is dialed, and I have burned a few of these spools without a liner-clogging tangle.
This is the practice spool. When you are learning aluminum MIG and your first ten beads are going to be garbage anyway, you want the garbage to cost as little as possible. Blue Demon gets you there, and the leftover half spool will still be useful once your settings stop fighting you.
Pros
- One of the most affordable genuine ER5356 options
- .035″ handles sheet and plate across positions
- All-position wire: flat, vertical, overhead
- 38 ksi and saltwater resistance from the 5356 alloy
- One-pound spool fits every standard spool gun
- Clean bead once the machine settings are right
- Cheap enough to learn on without feeling it
- Easy to find and reorder when the spool runs out
Cons
- Packaging never mentions you need argon
- One-pound size only; no bulk option in this listing
- Feed finish can vary slightly spool to spool
4. HARRIS 05356F1 ER5356 Aluminum MIG Welding Wire – Best Premium ER5356 Wire
Best Premium ER5356 Wire
HARRIS 05356F1 ER5356 Aluminum MIG Welding Wire
Harris is the brand welders argue about least. The 05356F1 is their .035 ER5356 on a one-pound spool, and it is the wire that shows up in shops where a failed weld means a call back. AWS A5.10 qualified, all-position, and boringly consistent. That consistency is the entire product.
| Diameter: | .035″ | Spool Weight: | 1 lb |
| AWS Class: | ER5356 | Shielding Gas: | 100% Argon |
| Melting Range: | 1060–1175°F | Tensile Strength: | 38 ksi |
| Material: | Aluminum | Process: | MIG |
| Manufacturer: | Harris Products Group | Price: | See Amazon |
The specs read like every other 5356: about 38 ksi tensile, high shear strength, saltwater-rated corrosion resistance. The difference is in how it feeds and how it lays. Harris runs the wire clean, and the finished bead is smooth with very little spatter, which is exactly what you want on visible work like boats, truck boxes, and pressure vessels.
Setup is standard: pure argon at 20 to 30 cubic feet per hour, DCEP. Nothing special required, which is the point. A premium wire that needed exotic settings would be a liability. This one drops into the same machine settings as budget 5356 and simply behaves a bit better under the hood.
Where the price difference pays off is repeatability. Every spool winds evenly, every spool runs the same, and you can weld the same joint a hundred times without chasing the wire as a variable. If a weld fails, you get to look at the machine, the prep, and your own hands. The wire is not on the list of suspects.
One small thing: the hole in the center of the spool runs smaller than the product photos suggest. Most spool gun hubs take it without complaint, but if your hub is tight, check the fit before you order five spools. It is the only gripe I have heard about this wire, and it is a packaging detail, not a weld issue.
Buy this if your aluminum work needs to look professional or get inspected. For a weekend repair you can absolutely get by with cheaper wire. But the first time a customer photographs a weld you made, the extra few dollars per spool stop feeling like an expense.
Pros
- AWS A5.10 qualified, all-position 5356
- About 38 ksi tensile with high shear strength
- Saltwater-rated; proven in marine and truck work
- Feeds evenly and lays a low-spatter bead
- Runs on plain argon at 20 to 30 CFH
- Consistent spool after spool
- Industry mainstay; easy to source anywhere
- The weld quality is visible on the finished part
Cons
- Costs more per pound than budget 5356
- Spool arbor hole runs smaller than the photos show
- One-pound spool means frequent swaps in production
5. (Processed In USA) M-4043 ER4043 Aluminum Welding Wire – Best Bulk ER4043 Value
Best Bulk ER4043 Value
(Processed In USA) M-4043 ER4043 Aluminum Welding Wire
The M-4043 is the bulk play on this page: fifteen pounds of ER4043 in 3/64-inch diameter on a full-size roll. Kiswel marks it Processed In USA, which some buyers care about and some do not. What everyone cares about is the per-pound price, and on a big spool it drops hard compared to the one-pound options.
| Diameter: | 3/64″ | Spool Weight: | 15 lb |
| AWS Class: | ER4043 | Shielding Gas: | 100% Argon |
| Melting Range: | 1065–1170°F | Tensile Strength: | 27 ksi |
| Material: | Aluminum | Process: | MIG |
| Manufacturer: | Kiswel | Price: | See Amazon |
3/64 inch is roughly .047, and it exists for a reason. Thicker wire carries more amperage and deposits metal fast, which is what you want on plate and castings. You will want a machine that can push 200 amps or more, plus a spool gun or push-pull setup to handle the roll. This is production wire, not a starter spool.
Being ER4043, it brings silicon to the puddle, and the puddle behaves: it wets out on castings, tolerates less-than-perfect cleaning, and leaves a bright weld with low spatter. Tensile is about 27 ksi, so keep it away from structural and marine work. For cosmetic welds, repairs, and general fab on 6xxx parts, it is the forgiving choice.
The big spool changes how you work. You stop counting how much wire a repair will burn and just run beads. Fewer changeovers, less downtime, and the roll sits on a proper hub instead of rattling around in a tool drawer. Keep it dry and covered between jobs, same as any aluminum wire.
The catch with 15 pounds is commitment. You are locking into one alloy and one diameter for a while. If your work is mixed, a three-pack of one-pound spools might fit better. If you know you are going to weld aluminum all season, this is the cheapest way to do it by a wide margin.
One honest note: this listing is newer than the rest and does not have much of a review history yet. The wire itself is clean, feeds steadily, and does what ER4043 should. Just do not expect a thousand Amazon reviews to lean on before you buy.
Pros
- Per-pound price beats every one-pound spool here
- 3/64″ lays down metal fast on plate and castings
- ER4043 puddle is forgiving on less-than-clean aluminum
- Bright, low-spatter weld on cosmetic work
- Fewer spool changeovers in the middle of a project
- Full-size roll runs on standard hubs and spool guns
- Sealed packaging keeps the roll dry in storage
- Processed In USA labeling, if that matters for your shop
Cons
- Fifteen pounds of one alloy is a real commitment
- 3/64″ burns through thin sheet if you are not careful
- Listing is new, so there is little track record to judge it by
Types of Aluminum and Aluminum Wire
So once you get your hand s on soft metal like aluminum, you have to take a different approach as towards other types of metal. So taking your time and choosing the correct wire used for welding is not a waste of time. There are different series aluminum wire but pure aluminum is not used as it is too soft to be used in casted parts. So in order to match the filler metal and stabilize the aluminum, other alloys are used. They are usually sold as 1 lb spool.
Both beginner and experienced welders will use a certain series aluminum alloy. The most common ones that you will definitely be using are the 4,000 Series, the 5,000 Series, and 6, 000 Series aluminum base.
The 4,000 series aluminum alloy has silicon added to it. the 5,000 aluminum series alloy has magnesium. But the 6,000 aluminum series alloy comes with both silicon and magnesium added to the mix.
Basically what you need to do when welding aluminum is to match the filler metal with the additive added to the aluminum alloys. The 4043 wire and the 5356 are the two best types of wires used for MIG welding aluminum.
ER 4043
The alloy 4043 wire is a general-purpose aluminum wire perfect for making brighter and shinier finishes. It includes silicon, making it a bit more forgiving to the person doing the work. However, this type of welder aluminum is going to produce welds that are more susceptible to cracking. It is usually used for 4,000 and 6,000 series aluminum alloys.
ER 5356
The 5356 is a welding wire that is, although more difficult to weld with, much stronger than the 4043 wire. Also, it is considered as the best wire to use as it has a wider array of usage. Even though this is a general-purpose aluminum wire it has found its usage in welding boats due to not being susceptible to saltwater. But it can also be used for fixing bicycles, car parts, or pressure vessels.
ER 4043 Vs. ER 5356
ER 4043
- Used for 4000 and 6000 series aluminum alloys.
- Aluminum filler with 5% silicon added.
- Darker weld post anodizing color.
- Suitable for service temperatures above 150 Deg, F.
- A softer alloy in the form of spooled wire,
- Generally tend to produce welds with improved cosmetic appearance.
- Will typically provide a higher rating for weldability and provide slightly lower crack sensitivity.
ER 5356
- Used for 5000 series aluminum alloys.
- Aluminum filler with 5% magnesium added.
- Brighter weld post anodizing color.
- Because of its 5% magnesium content is not suitable for these elevated temperature applications.
- Has more shear strength.
- Has higher ductility.
- Has higher corrosive and saltwater resistance, therefore used for welding boats.
Why buy Brand Name Aluminum Welding Wire
There are plenty of reasons why choosing brand name wires is better than buying cheap, off-brand stuff. You might come across some wire which is damaged. Some have even used wire with spool wound too tightly so it jumps off the spool gun to fast. Or there are situations when the wire is to loose so to the opposite happens.
Poor wire can also cause burn back on your contact tip, causing you to ruin your aluminum weld. So don’t try to save money as you might end causing more damage than good by doing so. Also, for you to get the best results when welding aluminum using a spool gun is best.
Combined with a good brand and using a spool gun will save you a lot of time and stress. We understand the reason if you want to save money, but in this case, it would be wise to go for the quality.
Furthermore, there is a common misconception about an aluminum flux core wire. However, something like that does not exist as AWS does not have filler specifications for aluminum flux-cored GMAW wires.
How do I Store My Aluminum Welding Wire?
Properly storing your aluminum wire can make a whole lot of difference in terms of its quality. If exposed to the air, aluminum tends to oxidize. So welding aluminum with a compromised wire will result in film coating with more soot coming off as you aluminum weld.
More so, it will create wire feed and electrical resistance and you will have generally difficulty laying down the wire. Inexperienced welders will think that something is worth with their welder and even go as far as changing the spool gun or the contact tips.
But a lot of them tend to forget that improper care of the aluminum wire can also lead to problems. Thus the best way to preserve your wire is to keep in a tightly-sealed container where no air can get in. Keep it away from excessive cold or dampness.
Even by simply moving a cold wire to a warmer place can result in condensation building up inside and damaging the wire further. So keep it in a place where the temperature is stable
Frequently Asked Questions
What does ER4043 stand for?
ER4043, also called AISi5, is one of the types of aluminum filler metals consisting of 5% silicon. It is commonly used for MIG welding aluminum and for the TIG setup. This type of aluminum filler wire is used for 3003, 3004, 5052, 6061, 6063 types but also comes in handy when casing alloy on 43, 355, 356, and 214.
What is the difference between 4043 and 5356 aluminum?
The main difference is that 4043 has 5% silicon added to it, while the aluminum 5356 one has 5% magnesium. These two are the most commonly used filler materials when welding aluminum and in some cases, certain structural elements can be welded by both. But generally speaking, the two are different and a welder should follow the selection chart to determine which one would be used best.
Does welding aluminum weaken it?
When welding aluminum a weld in the aluminum alloy tends to be weaker than the alloy being welded. This is not the case with carbon steel or other types of materials. But when it comes to aluminum a weld cannot be made as strong as the parent material.
Can you weld aluminum to steel?
Welding aluminum to steel is possible, but the process requires different types of techniques to be used. The most reliable way of doing so is through arc welding and friction welding. The biggest problem in welding aluminum to steel is that the materials have different physical properties in terms of metallurgy and also come with different conductivity and melting temperatures.
Conclusion
Keep in mind that aluminum welding by itself is not as easy as you think. One does need to have a steady hand as well as being able to use good technique. But an important factor in successful aluminum welding is the choice of your aluminum wire. Welding thin gauge aluminum or one that is thinner than 14 gauge requires to think hard about the wire you are going to use even though it comes at an extra cost.
Make sure that you have all the pieces of information in regards to the materials that you are working on. That will enable you to choose the correct type of wire. It can greatly influence your final product and make your work a lot cleaner and better. Consider the given aluminum welding wires for your next project.
