Lincoln Electric SuperGlaze ER4043 in 0.030 in (0.8 mm) diameter in a 20 × 1 lb mini-spool pack (ED030307) is the choice for MIG welding thin aluminum sheet and light extrusions where arc control and minimum heat input are paramount. Classified AWS A5.10/A5.10M ER4043, this wire's 5% silicon chemistry provides excellent crack resistance, fluid puddle flow, and clean bead appearance on 6xxx-series alloys and aluminum casting alloys. The 0.030 in diameter operates at lower amperages than 0.035 in or 3/64 in wire, reducing the risk of burn-through on material as thin as 0.040 in (1 mm) gauges. The 1 lb plastic mini-spool format allows direct loading into compact spool guns without adapters, making it ideal for mobile repair and multi-station shops. WeldingMart ships as an authorized Lincoln Electric distributor. Browse the full welding wire collection.
| Property | Value |
|---|---|
| AWS Classification | ER4043 per AWS A5.10/A5.10M |
| Lincoln Part Number | ED030307 |
| Wire Diameter | 0.030 in (0.8 mm) |
| Package | 20 × 1 lb (0.45 kg) plastic mini-spools |
| Spool Diameter | 4 in (100 mm) |
| Base Alloy Series | 4xxx (Al-Si) |
| Silicon Content | 4.5–6.0% Si |
| Polarity | DCEP (electrode positive) |
| Shielding Gas | 100% Argon |
| Tensile Strength (as-welded) | ≥ 165 MPa (24,000 psi) |
| Elongation | ≥ 18% |
| Welding Process | GMAW (MIG), compact spool gun |
| Conformances | AWS A5.10/A5.10M, ASME SFA-5.10 |
- Thin sheet automotive body: Hood skins, door panels, and trunk lids in 5052-H32 or 6111-T4 gauges from 0.040–0.080 in where burn-through control is the primary concern.
- Marine trim and hardware: Aluminum cleats, rub rails, and trim extrusions in 6063-T5 or 6061-T6 where a neat, compact bead on thin walls is required.
- Aluminum casting spot repair: Small defect fills in die cast and permanent mold castings (356, A356) where the minimum heat input of 0.030 in wire reduces distortion and cracking.
- HVAC and refrigeration: Aluminum coil headers and connector tubes in 3xxx and 6xxx alloys — fine wire enables tight parameter control in automated spool gun stations.
- Electronics enclosures: Aluminum chassis, heat sinks, and rack components in 6061 or 6063 machined and welded assemblies requiring cosmetically clean welds.
- Art, architectural metalwork, and signage: Custom aluminum fabrication where fine wire and spool gun accessibility enable detailed work not practical with larger diameters.
Thin aluminum is the most challenging aluminum welding situation. Key considerations for 0.030 in ER4043:
| Parameter | 0.030 in ER4043 Setting |
|---|---|
| Drive Roll Type | U-groove aluminum, properly sized for 0.030 in |
| Contact Tip Bore | 0.035 in (slightly oversized) |
| Shielding Gas | 100% Argon at 18–22 CFH |
| Arc Transfer Mode | Short arc / globular; spray above ≈ 130 A |
| Travel Speed | Fast — keep moving to prevent heat buildup |
| Backstepping | Useful on butt joints to reduce distortion |
| Tack Weld Spacing | 2–3 in (50–75 mm) for thin-sheet fit-up |
Aluminum has very high thermal conductivity — heat spreads rapidly from the weld zone into the base metal. Preheat thin sections only when ambient temperature is below 40 °F (4 °C). For material above 0.080 in, 0.035 in wire is generally more efficient. Source: Lincoln Electric Aluminum MIG Technical Guidance.
| Material Thickness | WFS (in/min) | Voltage (V) | Amperage | Gas Flow |
|---|---|---|---|---|
| 0.040 in (1.0 mm) | 120–180 | 15–17 | 55–80 A | 100% Ar, 18 CFH |
| 0.062 in (1.6 mm) | 170–230 | 17–19 | 75–110 A | 100% Ar, 20 CFH |
| 1/8 in (3.2 mm) | 230–300 | 19–21 | 100–145 A | 100% Ar, 22 CFH |
- What is the thinnest aluminum I can weld with 0.030 in ER4043?
- With 0.030 in ER4043 and proper spool-gun settings, you can weld aluminum sheet as thin as 0.040 in. For thinner gauges, TIG welding gives better control.
- Why choose ER4043 over ER5356 for thin aluminum?
- ER4043's silicon chemistry creates a more fluid puddle at lower heat input, reducing burn-through and crater cracking. For thin 6xxx-series or cast alloy work, ER4043 is preferred.
- What is the best way to prevent burn-through when MIG welding thin aluminum?
- Use 0.030 in wire, fast travel speed, push angle, back-stepping, and copper backing on butt joints. Clean the base metal thoroughly before welding.
- Are the 1 lb mini-spools in ED030307 compatible with all spool guns?
- The 4-inch mini-spools fit Lincoln Magnum Pro 100SG and most standard compact spool guns. Verify your gun handles 0.030 in diameter wire before purchasing.
- Is ER4043 appropriate for welding aluminum to steel or cast iron?
- No. ER4043 is for aluminum-to-aluminum welding only. Aluminum-to-steel dissimilar joints require friction stir welding or mechanical fastening — not fusion welding with aluminum filler.
Related products: SuperGlaze ER4043 1/16 in, 20 lb (ED030281) | SuperGlaze ER5356 0.035 in, 20×1 lb (ED030312) | All Welding Wire