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Aerospace Lightweight Aluminum Alloy Wire

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Product Description

Aluminum filler metals optimized for maximum weight reduction in aerospace structures while maintaining superior structural integrity. This includes high-purity ER5183 for high strength-to-weight joints, or specialized third-generation Al-Li (Aluminum-Lithium) alloy wires that precisely match Al-Li base metals (e.g., 2050,2060). These wires feature stringent quality control over volatile elements (like Li) and minimal inclusion content to meet strict airworthiness standards and maximize the weight-saving potential of the material system.

DB Certification CE Certification ABS Certification DNV Certification CCS Certification

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20+ Years Experience

Over two decades of aluminum alloy wire production expertise

International Certifications

DB, CE, ABS, DNV, CCS and other authoritative certifications

200MT Monthly Capacity

Large-scale production with consistent quality

Global Export

Exporting to over 30 countries worldwide

Introduction

In aerospace, every kilogram saved translates directly into fuel efficiency and payload capacity. Our lightweight filler metals are critical enablers for next-generation aircraft and space vehicles. We focus on providing high-strength, low-density consumables, including advanced Al-Li wires that reduce density by up to 10% compared to traditional aerospace alloys. By guaranteeing material cleanliness and strict dimensional tolerance, we support automated welding processes that achieve defect-free joints essential for flight certification and maximum weight reduction.

Specification

Key MetricHigh Strength-to-Density Ratio
Alloy FocusER5183, Al-Li (Aluminum-Lithium) Wires
Required StandardsAMS 2417, MIL-STD-2219 (Traceability and Cleanliness)
Quality FocusLow Oxide/Inclusion Content, Tightly Controlled Volatile Elements
Density ReductionUp to 10% with Al-Li filler systems

Applications and Solutions

  • Aircraft Fuselage and Wing Panels: Welding primary and secondary structures using Al-Li or high-strength Al-Mg alloys.

  • Space Launch Vehicle Tanks: Fabrication of cryogenic fuel tanks (Liquid Oxygen/Hydrogen) where toughness and minimal mass are non-negotiable.

  • Internal Aircraft Components: Welding seating tracks, bulkheads, and pressure domes where structural efficiency is critical.

  • Repair of Composite Structures: Used in hybrid joints between aluminum and carbon fiber components (when compatible coatings are present).

FAQ

  • Q: What is the main challenge when welding Al-Li alloys?A: Lithium is highly reactive and volatile. The weld process must be extremely clean, use high-purity shielding gas, and the filler wire must be perfectly dry and oxide-free to prevent severe porosity and fuming.
  • Q: Which conventional filler is used for general aerospace lightweight structures?A: ER5183 is the most common filler for high-strength, lightweight aerospace-grade 5XXX and 5XXX base metals due to its excellent strength and toughness.
  • Q: Does lightweight wire mean less strong?A: No. The strength-to-weight ratio is maximized. The specialized alloys achieve high strength despite the lower density, sometimes exceeding the performance of traditional, denser structural alloys.

Advantages and Core Features

  • Maximum Weight Savings: Utilization of low-density alloying elements (Lithium, Magnesium) to directly reduce the joint mass.

  • Superior Strength: High Mg content (ER5183) or Li-based strengthening mechanisms provide excellent tensile and yield strength.

  • Enhanced Stiffness: Al-Li systems offer higher Young's Modulus (stiffness) than conventional aluminum, improving structural performance.

  • Full Traceability: All lots are certified to aerospace standards, ensuring complete material transparency and audit readiness for flight-critical parts.

Material Selection Guide

For aerospace lightweight applications, prioritize Al-Li fillers when joining Al-Li base metals for maximum weight benefit. For 5XXX base metals (5083, 5456), use ER5183. Always ensure the filler is explicitly certified to relevant AMS or military specifications for aerospace use.

About Us

Coming From China, Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is China Aerospace Lightweight Aluminum Alloy Wire Manufacturers and Wholesale Aerospace Lightweight Aluminum Alloy Wire OEM/ODM Suppliers. We are located in the industrial zone of Puyang Town, Xiaoshan District, Hangzhou, Zhejiang Province. It is a high-technology enterprise specializing in the research, development and manufacturing of high-performance. The company has more than 20 years of aluminum alloy wire production experience, with international advanced manufacturing equipment, complete testing equipment,stable production process and strict quality control system.
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