SPECIFICATION FOR ALUMINUM AND ALUMINUM

ALLOY ELECTRODES FOR SHIELDED METAL ARC

WELDING
SFA-5.3

(Identical with AWS Specification A5.3-91)

1. Scope the product, the manufacturer certifies that the product

meets the requirements of this specification.3
This specification prescribes requirements for the
classification of aluminum and aluminum alloy elec-
trodes for shielded metal arc welding.
5. Units of Measure and Rounding-Off
Procedure
SECTION A — GENERAL REQUIREMENTS
5.1 U.S. Customary Units are the standard units of
2. Classification measure in this specification. The SI Units are given
2.1 The electrodes covered by this specification are as equivalent values to the U.S. Customary Units. The
classified according to the chemical composition of the standard sizes and dimensions in the two systems are
core wire as specified in Table 1, and mechanical not identical, and for this reason conversion from a
properties of a groove weld. standard size or dimension in one system will not
always coincide with a standard size or dimension in
2.2 An electrode classified under one classification the other. Suitable conversions, encompassing standard
shall not be classified under any other classification in sizes of both, can be made, however, if appropriate
this specification. tolerances are applied in each case.

3. Acceptance 5.2 For the purpose of determining conformance with

this specification, an observed or calculated value shall
Acceptance1of the electrode shall be in accordance be rounded to the nearest 1000 psi (7 MPa) for tensile
with the provisions of ANSI /AWS A5.01, Filler Metal and yield strength, and to the “nearest unit” in the last
Procurement Guidelines.2 right-hand place of figures used in expressing the
limiting value for other quantities in accordance with
4. Certification the rounding-off method given in ASTM E29, Practice
for Using Significant Digits in Test Data to Determine
By affixing the AWS specification and classification Conformance with Specifications.4
designations to the packaging, or the classification to
3 See A4, Certification (in the Appendix), for further information
1 See A3, Acceptance (in the Appendix), for further information concerning certification and the testing called for to meet this
concerning acceptance, testing of the material shipped, and requirement.
ANSI /AWS A5.01, Filler Metal Procurement Guidelines. 4 ASTM Standards can be obtained from the American Society for
2 AWS Standards can be obtained from the American Welding Society, Testing and Materials, 1916 Race Street, Philadelphia, Pennsylva-
550 N.W. LeJeune Road, P.O. Box 351040, Miami, Florida 33135 nia 19103

53
 SFA-5.3

TABLE 1
CHEMICAL COMPOSITION REQUIREMENTS FOR CORE WIRE (WEIGHT PERCENT)a,b

Other Elements
AWS UNS
Classification Designationc Si Fe Cu Mn Mg Zn Ti Be Each Total Al
E1100 A91100 (d) (d) 0.05–0.20 0.05 — 0.10 — 0.0008 0.05 0.15 99.00 mine
E3003 A93003 0.6 0.7 0.05–0.20 1.0–1.5 — 0.10 — 0.0008 0.05 0.15 Remainder

54
E4043 A94043 4.5–6.0 0.8 0.30 0.05 0.05 0.10 0.20 0.0008 0.05 0.15 Remainder
NOTES:
a. The core wire, or the stock from which it is made, shall be analyzed for the specific elements for which values are shown in this table. If the presence of other elements is indicated in the
1998 SECTION II

course of work, the amount of those elements shall be determined to ensure that they do not exceed the limits specified for “Other Elements.”
b. Single values are maximum, except where otherwise specified.
c. SAE/ASTM Unified Numbering System for Metals and Alloys.
d. Silicon plus iron shall not exceed 0.95 percent.
e. The aluminum content for unalloyed aluminum is the difference between 100.00 percent and the sum of all other metallic elements present in amounts of 0.010 percent or more each,
expressed to the second decimal before determining the sum.
 PART C — SPECIFICATIONS FOR WELDING RODS,
ELECTRODES, AND FILLER METALS SFA-5.3

TABLE 2
REQUIRED TESTS

Electrode

Size
AWS Chemical Tension Bend
Classication in. mm Analysisa Testb Testc

6
3⁄ 2.4 X

5 6
32
1⁄ d

6
8 3.2 X d
E1100, 5⁄
32 4.0 X
E3003,

6
3⁄ 4.8 X
16
and 1⁄
4 6.4 X
E4043 5⁄ e
16 8.0 X e
3⁄ 9.5 X
8

NOTES:
a. Chemical analysis of the core wire or the stock from which it is made.
b. Two transverse specimens (Figure 2).
c. Two transverse specimens — one face and one root (Figure 3).
d. Electrodes 5⁄32 in. (4.0 mm) and smaller shall be classified on the basis of the results obtained with the
5⁄
32 in. (4.0 mm) size of the same classification.
e. Electrodes 3⁄16 in. (4.8 mm) and larger shall be classified on the basis of the results obtained with the
1⁄ in. (6.4 mm) size of the same classification.
4

SECTION B — TESTS, PROCEDURES, AND and e) using base metal of the appropriate type specified
REQUIREMENTS in Table 3. Testing of the assembly shall be as specified
in Sections 10, Tension Test, and 11, Bend Test.
6. Summary of Tests
The tests required for each classification are specified 8.3 The test assembly shall be preheated to a tempera-
in Table 2. The purpose of these tests is to determine ture between 350°F and 400°F (175°C and 205°C),
the chemical composition of the core wire and the and shielded metal arc (SMA) welded from one side,
mechanical properties of the weld. The base metal in the flat position. The test assembly should be precam-
for the weld test assemblies, the welding and testing bered or restrained so that warping due to welding will
procedures to be employed, and the results required, not cause the finished test assembly to be out-of-plane
are given in Sections 8 through 11. by more than 5 degrees. If the completed test assembly
is more than 5 degrees out-of-plane it shall be straight-
7. Retest ened at room temperature.

If the results of any tests fail to meet the requirement,

that test shall be repeated twice. The results of both
tests shall meet the requirement. Specimens or samples
for retest may be taken from the original test assembly 9. Chemical Analysis
or sample, or from a new test assembly or sample. 9.1 A sample of the core wire, or the stock from
For chemical analysis, retest need be only for those which it is made, shall be prepared for chemical analysis.
specific elements that failed to meet the test requirement.
9.2 The sample shall be analyzed by accepted analyti-
8. Weld Test Assembly cal methods. The referee method shall be ASTM E34,
Standard Methods for Chemical Analysis of Aluminum
8.1 One weld test assembly is required. It is the and Aluminum Alloys.
groove weld in Fig. 1 for mechanical properties of the
welded joint.
9.3 The results of the analysis shall meet the require-
8.2 Preparation of the weld test assembly shall be ments of Table 1 for the classification of electrode
as prescribed in 8.3, Fig. 1, and Table 2 (Footnotes d under test.

55
SFA-5.3 1998 SECTION II

FIG. 1 GROOVE WELD TEST ASSEMBLY FOR MECHANICAL PROPERTIES

56
 PART C — SPECIFICATIONS FOR WELDING RODS,
ELECTRODES, AND FILLER METALS SFA-5.3

TABLE 3
BASE METAL FOR TEST ASSEMBLIES

Electrode Base Metal

AWS Aluminum ASTM UNS
Classification Alloya Specification Designation

E1100 1100 B209 A91100

E3003, E4043 3003b B209 A93003
a. Aluminum Association Registration Numbers.
The Aluminum Association, Inc.
900 19th Street, N.W.
Suite 300
Washington, DC 20006
b. When welding 3003 with E4043 electrodes, 3003-0 (annealed temper) plate is preferred.

FIG. 2 TENSION TEST SPECIMEN

10. Tension Test 10.3 The results of the tension test shall meet the
requirements specified in Table 4.
10.1 Two transverse tension test specimens shall be
machined from the groove weld described in Section
8, Weld Test Assembly, and shown in Fig. 1. The
dimensions of the specimens shall be as specified in 11. Bend Test
Fig. 2.
11.1 One transverse face and one transverse root
10.2 The specimens shall be tested in the manner bend specimen, as required in Table 2, shall be machined
described in the tension test section of ANSI /AWS from the groove weld test assembly described in Section
B4.0, Standard Methods for Mechanical Testing of 8 and shown in Fig. 1. The dimensions of the specimens
Welds. shall be as shown in Fig. 3.

57
SFA-5.3 1998 SECTION II

TABLE 4 which show no evidence of inclusions or other fusion-

TENSION TEST REQUIREMENTS type discontinuities, shall not be a basis for rejection.

Tensile Strength,
Min.
AWS SECTION C — MANUFACTURE,
Classification psi MPa IDENTIFICATION, AND PACKAGING
E1100 12000 82.7 12. Method of Manufacture
E3003 14000 96.5
E4043 14000 96.5 The electrodes classified according to this specifica-
* Fracture may occur in either the base metal or the weld metal.
tion may be manufactured by any method that will
produce electrodes that meet the requirements of this
specification.

11.2 The specimens shall be tested in the manner 13. Standard Sizes and Lengths
described in the guided bend test section of ANSI /AWS 13.1 Standard sizes (diameter of the core wire) and
B4.0 by bending them uniformly through 180° over a lengths of electrodes are shown in Table 5.
1-1 /4 in. (32 mm) radius in any suitable jig. Two
standard bend test jigs are shown in Fig. 4. Positioning 13.2 The diameter of the core wire shall not vary
of the face bend specimen shall be such that the face more than 60.002 in. (60.05 mm) from the diameter
of the weld is in tension. Positioning of the root bend specified. The length shall not vary more than 63 /8
specimen shall be such that the root of the weld in is in. (69.5 mm) from that specified.
tension. For both types of transverse bend specimen,
the weld shall be at the center of the bend.
14. Core Wire and Covering
11.3 Each specimen, after bending, shall conform to
14.1 The core wire and covering shall be free of
the 1-1 /4 in. (32 mm) radius, with an appropriate
defects that would interfere with uniform deposition of
allowance for springback, and the weld metal shall
the electrode.
show no crack or other open defect exceeding 1 /8 in.
(3.2 mm) measured in any direction on the convex 14.2 The core wire and the covering shall be concen-
surface, when examined with the unaided eye. Cracks tric to the extent that the maximum core-plus-one-
that occur on the corners of a specimen during testing covering dimension shall not exceed the minimum

FIG. 3 BEND TEST SPECIMEN

58
PART C — SPECIFICATIONS FOR WELDING RODS,
ELECTRODES, AND FILLER METALS SFA-5.3

FIG. 4 BEND TEST JIGS

59
SFA-5.3 1998 SECTION II

FIG. 4 BEND TEST JIGS (CONT’D)

TABLE 5
STANDARD SIZES

Diameter of Standard
Core Wire, Lengths

AWS Classification in. mm in. mm

6
5 6
3⁄ (0.094) 2.4
32
1⁄ (0.125) 3.2
8
5⁄ 14 350
32 (0.156) 4.0
E1100, E3003, and E4043 3⁄ (0.188) 4.8
16
1⁄ (0.250) 6.4

6
4
5⁄ (0.312) 8.0 18 450
16
3⁄ (0.375) 9.5
8

60
 PART C — SPECIFICATIONS FOR WELDING RODS,
ELECTRODES, AND FILLER METALS SFA-5.3

core-plus-one covering dimension by more than the normal use, the numbers and letters are legible both
following: before and after welding.
(1) Seven percent of the mean dimension in size
3 /32 in. (2.4 mm) 16.4 The prefix letter “E” in the electrode classifica-
(2) Five percent of the mean dimension in sizes 1 /8 tion may be omitted from the imprint.
in. (3.2 mm) and 5 /32 in. (4.0 mm) 16.5 In lieu of imprinting, electrodes may be identified
(3) Four percent of the mean dimension in sizes by the following:
3 /16 in. (4.8 mm) and larger (1) Attaching to the bare grip end of each electrode a
Concentricity may be measured by any suitable pressure sensitive tape bearing the classification number.
means. (2) Embossing the classification number on the bare
14.3 The coverings shall be such that they are not grip end of each electrode. In this case, a slight flattening
readily damaged by ordinary handling, and they shall of the grip end will be permitted in the area of the
not blister when heated to 400°F (200°C)〉 They shall embossing.
be consumed uniformly during welding and shall not
blister or melt back from the core wire. The flux
17. Packaging
residue they produce shall be readily removable.
17.1 Electrodes shall be suitably packaged to protect
them from damage during shipment and storage under
15. Exposed Core normal conditions.
15.1 The grip end of each electrode shall be bare
17.2 Standard package weights shall be 1 lb (0.45
(free of covering) for a distance of not less than 1 /2
kg), 5 lb (2.3 kg) and 10 lb (4.5 kg) net weight.
in. (13 mm), nor more than 1-1 /4 in. (30 mm), for
Other package weights meet the requirements of this
electrodes 5 /32 in. (4.0 mm) and smaller, and not less
specification when agreed by the purchaser and supplier.
than 3 /4 in. (19 mm) nor more than 1-1 /2 in. (35
mm) for electrodes 3 /16 in. (4.8 mm) and larger, to
provide for electrical contact with the electrode holder. 18. Marking of Packages
15.2 The arc end of each electrode shall be sufficiently 18.1 The following product information (as a mini-
bare and the covering sufficiently tapered to permit mum) shall be legibly marked on the outside of each
easy striking of the arc. The length of the bare portion unit package:
(measured from the end of the core wire to the location (1) AWS specification and classification designation
where the full cross section of the covering is obtained) (year of issue may be excluded)
shall not exceed 1 /8 in. (3 mm) or the diameter of (2) Supplier’s name and trade designation
the core wire, whichever is less. Electrodes with chipped (3) Size and net weight
coverings near the arc end, baring the core wire no (4) Lot, control, or heat number
more than the lesser of 1 /4 in. (6 mm) or twice the
diameter of the core wire, meet the requirements of 18.2 The following precautionary information (as a
this specification, provided no chip uncovers more than minimum) shall be prominently displayed in legible
50 percent of the circumference of the core. print on all packages of electrodes, including individual
unit packages enclosed with a larger package.

16. Electrode Identification

WARNING:
All electrodes shall be identified as follows:
16.1 At least one imprint of the electrode classification PROTECT yourself and others.
shall be applied to the electrode covering within 2-
1 /2 in. (65 mm) of the grip end of the electrode.
READ and understand this information.

16.2 The numbers and letters of the imprint shall FUMES AND GASES can be dangerous to your
be of bold block type of a size large enough to be health.
legible.
ARC RAYS can injure eyes and burn skin.
16.3 The ink used for imprinting shall provide suffi-
cient contrast with the electrode covering so that, in ELECTRIC SHOCK can kill.

61
SFA-5.3 1998 SECTION II

O Before use, read and understand the manufacturer’s

instructions, manufacturer’s Material Safety Data
Sheets (MSDSs), and your employer’s safety prac-
tices.
O Keep your head out of the fumes.
O Use enough ventilation, exhaust at the arc, or both
to keep fumes and gases away from your breathing
zone and the general area.
O Wear corrective eye, ear and body protection.
O See American National Standard Z49.1, Safety in
Welding and Cutting, published by the American
Welding Society, 550 N.W. LeJeune Road, P.O.
Box 351040, Miami, Florida 33135; OSHA Safety
and Health Standards, 29 CFR 1910, available
from the U.S. Government Printing Office, Wash-
ington, DC 20402

DO NOT REMOVE THIS INFORMATION

62
 PART C — SPECIFICATIONS FOR WELDING RODS,
ELECTRODES, AND FILLER METALS SFA-5.3

Appendix
Guide to Specification for Aluminum and Aluminum Alloy
Electrodes for Shielded Metal Arc Welding

(This Appendix is not a part of ANSI /AWS A5.3-91, Specification for Aluminum and Aluminum Alloy Electrodes for Shielded
Metal Arc Welding, but is included for information purposes only.)

A1. Introduction fication, as specified in Schedule F, Table 1, of

ANSI /AWS A5.01. Testing in accordance with any
The purpose of this guide is to correlate the electrode
other Schedule in that Table must be specifically re-
classifications with their intended applications so the
quired by the purchase order. In such cases, acceptance
specification can be used effectively. Reference to appro-
of the material shipped shall be in accordance with
priate base metal specifications is made whenever that
those requirements.
can be done and when it would be helpful. Such
references are intended only as examples rather than
complete listings of the materials for which each filler
metal is suitable.

A2. Classification System A4. Certification

The system for identifying the electrode classifications The act of placing the AWS specification and classi-
in this specification follows the standard pattern used fication designations on the packaging enclosing the
in other AWS filler metal specifications. The letter E product, or the classification on the product itself,
at the beginning of each classification designation stands constitutes the supplier’s (manufacturer’s) certification
for electrode. The numerical portion of the designation that the product meets all of the requirements of the
in this specification conforms to the Aluminum Associa- specification.
tion registration for the composition of the core wire The only testing requirement implicit in this certifica-
used in the electrode. tion is that the manufacturer has actually conducted
the tests required by the specification on material that
is representative of that being shipped and that material
A3. Acceptance
met the requirements of the specification. Representative
Acceptance of all welding materials classified under material, in this case, is any production run of that
this specification is in accordance with ANSI /AWS classification using the same formulation. “Certification”
A5.01, Filler Metal Procurement Guidelines, as the is not to be construed to mean that tests of any kind
specification states. Any testing a purchaser requires were necessarily conducted on samples of the specific
of the supplier, for material shipped in accordance with material shipped. Tests on such material may or may
this Specification, shall be clearly stated in the purchase not have been conducted. The basis for the certification
order, according to the provisions of ANSI /AWS A5.01. required by the specification is the classification test
In the absence of any such statement in the purchase of “representative material” cited above, and the “Manu-
order, the supplier may ship the material with whatever facturer’s Quality Assurance Program” in ANSI /AWS
testing normally is performed on material of that classi- A5.01.

63
SFA-5.3 1998 SECTION II

A5. Ventilation During Welding stored in a dry, clean location. Electrodes taken from
previously opened packages or those exposed to mois-
A5.1 Five major factors govern the quantity of
ture should be “conditioned” by holding them at 350°F
fumes in the atmosphere to which welders and welding
to 400°F (175°C to 205°C) for an hour before welding.
operators are exposed during welding:
After conditioning, they should be stored in a heated
(1) Dimensions of the space in which welding is
cabinet at 150°F to 200°F (66°C to 94°C) until used.
done (with special regard to the height of the ceiling)
(2) Number of welders and welding operators work-
A6.3 The minimum base metal thickness recom-
ing in that space
mended for shielded metal arc welding of aluminum
(3) Rate of evolution of fumes, gases, or dust, ac-
is 1 /8 in. (3.2 mm). For thicknesses less than 1 /4 in.
cording to the materials and processes used
(6.4 mm), no edge preparation other than a relatively
(4) The proximity of the welders or welding operators
smooth, square cut is required. Material over 1 /4 in.
to the fumes as the fumes issue from the welding zone,
(6.4 mm) should be beveled to a single-V-groove with
and to the gases and dusts in the space in which they
a 60 to 90 degree included angle. On very thick
are working
material, U-grooves may be used. Depending upon base
(5) The ventilation provided to the space in which
metal gauge, root-face thicknesses range between 1 /16
the welding is done
in. (1.6 mm) and 1 /4 in. (6.4 mm). A root opening
A5.2 American National Standard Z49.1, Safety in of 1 /32 in. to 1 /16 in. (0.8 to 1.6 mm) is desirable
Welding and Cutting (published by the American Weld- for all groove welds.
ing Society), discusses the ventilation that is required
during welding and should be referred to for details. A6.4 Because of the high heat conductivity of alumi-
Attention is drawn particularly to the Section of that num, preheating to 250°F to 400°F (120°C to 205°C)
document on Health Protection and Ventilation. is nearly always necessary on thick material to maintain
the weld pool and proper fusion. Preheating will also
help to avoid porosity due to too rapid cooling of the
A6. Welding Consideration weld pool at the start of the weld. On complicated
A6.1 Welding aluminum by the shielded metal arc welds, preheating is useful in avoiding distortion. Pre-
process is a well established practice. However, develop- heating may be done by a torch using oxygen and
ment of the gas shielded arc welding processes and acetylene or other suitable fuel gas, or by electrical
the many advantages of these processes offer has caused resistance heating. Mechanical properties of 6XXX se-
a shift away from the use of covered electrodes. This ries aluminum alloy weldments can be reduced signifi-
shift is expected to continue and the use of SMAW cantly if the higher preheating temperatures [350°F
for aluminum will dwindle. When shielded metal arc (177°C) or higher] are applied.
welding, a flux covered electrode is held in the standard
electrode holder and welding is done with direct current, A6.5 Single-pass SMA welds should be made when-
electrode positive (DCEP). Important factors to be ever possible. However, where thicker plates require
considered when welding aluminum with covered elec- multiple passes, thorough cleaning between passes is
trodes are moisture content of the electrode covering, essential for optimum results. After the completion of
and cleanliness of the electrode and base metal. Preheat any welding, the weld and work should be thoroughly
is usually required to obtain good fusion and to improve cleaned of residual flux. The major portion of the
soundness of the weld. Residual flux removal between residual flux can be removed by mechanical means,
passes is required to provide improved arc stability such as a rotary wire brush, slag hammer, or peening
and weld fusion. Complete removal of the residual flux hammer, and the rest by steaming or a hot-water rinse.
after welding is necessary to avoid corrosive attack in The test for complete removal of residual flux is to
service. swab a solution of five percent silver nitrate on the
weld areas. Foaming will occur if residual flux is
A6.2 The presence of moisture in the electrode present.
covering is a major cause of weld porosity. Dirt,
grease, or other contamination of the electrode can also A6.6 Interruption of the arc when shielded metal
contribute to porosity. The absorption of moisture by arc welding aluminum can cause the formation of a
the covering can be quite rapid, and the covering can fused flux coating over the end of the electrode. Re-
deteriorate after only a few hours exposure to a humid establishing a satisfactory arc is impossible unless this
atmosphere. For this reason, the electrodes should be formation is removed.

64
 PART C — SPECIFICATIONS FOR WELDING RODS,
ELECTRODES, AND FILLER METALS SFA-5.3

A7. Description and Intended Use of Electrodes other than 1100 and 3003 usually are not stocked
and must be specially ordered. For application where
A7.1 Electrodes of the E1100 classification produce
corrosion resistance is important, it may be advantageous
weld metal of high ductility, good electrical conductiv-
to use one of the gas shielded arc welding processes
ity, and a minimum tensile strength of 12 000 psi
for which a wider range of filler metal compositions
(82.7 MPa). E1100 electrodes are used to weld 1100,
is available.
1350(EC), and other commercially pure aluminum
alloys.
A8. Special Tests
A7.2 Electrodes of the E3003 classification produce
weld metal of high ductility and a minimum tensile It is recognized that supplementary tests may be
strength of 14 000 psi (96.5 MPa). E3003 electrodes necessary to determine the suitability of the electrodes
are used to weld aluminum alloys 1100 and 3003. for certain applications. In such cases, tests to determine
specific properties such as corrosion resistance, electrical
A7.3 The E4043 classification contains approximately conductivity, mechanical properties at elevated or cryo-
five percent silicon, which provides superior fluidity at genic temperatures, and suitability for welding different
welding temperatures, and for this reason is preferred combinations of aluminum base alloys may be required.
for general purpose welding. The E4043 classification
produces weld metal with fair ductility and a minimum A9. Chemical Analysis
tensile strength of 14 000 psi (97 MPa). E4043 elec-
trodes can be used to weld the 6XXX series aluminum The accepted and most widely used method for
alloys, the 5XXX series aluminum alloys (up to 2.5 chemical analysis is found in ASTM E227, Optical
percent Mg content), and aluminum-silicon casting Emission Spectrometric Analysis of Aluminum and Alu-
alloys, as well as aluminum base metals 1100, 1350(EC), minum Alloy by the Point-to-Plane Technique. This
and 3003. method analyzes a bulk sample and all elements simulta-
neously. The ASTM E34, Test Method for Chemical
A7.4 For many aluminum applications, corrosion Analysis of Aluminum and Aluminum Alloy prescribes
resistance of the weld is of prime importance. In such individual test methods for which each element is tested.
cases, it is advantageous to choose an electrode with The ASTM E34 test methods are used as a referee
a composition as close as practical to that of the base method if a dispute arises concerning a specific element
metal. For this use, covered electrodes for base metals analysis.

65