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Aluminium Filler Metal for Casting Repair

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Product Description

Aluminum filler metals specifically chosen for their high fluidity and tolerance for the variable, often silicon-rich chemistry of cast aluminum base metals (e.g., A356, 319, 357). ER4043 and ER4047 are the primary choices due to their high silicon content, which dramatically lowers the melting point and viscosity, allowing the filler metal to flow easily into tight flaws, cracks, and mold defects. The superior fluidity and short freezing range of these Al-Si alloys are essential for achieving complete fusion and crack mitigation in the stressed and chemically complex microstructure of aluminum castings.

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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

Repairing aluminum castings—such as engine blocks, transmission cases, and pump housings—is a daily necessity in automotive, marine, and industrial maintenance. Castings are inherently prone to porosity, internal stress, and hot tearing. Our casting repair consumables are designed to counteract these issues. By maximizing silicon, we provide a filler that wets the often highly oxidized surfaces well and helps relieve stress, minimizing the risk of the repair weld itself cracking, which is the most common failure mode in casting repair.

Specification

Alloy FocusER4043 (5% Si), ER4047 (12% Si)
Key PropertyHigh Fluidity, Crack Mitigation (Short Freezing Range)
Preferred ProcessTIG (GTAW) and TIG Pulse for precise heat control
Base Metal Compatibility3XX.X, A3XX.X (e.g., A356, 319, 357)
Repair TypeFixing porosity, shrinkage, cracks, and wear surfaces

Applications and Solutions

  • Automotive Engine Components: Repairing cracks in cylinder heads, engine blocks, and manifolds (often 319/356/357 alloys).

  • Foundry Repair: Repairing casting defects (shrinkage, porosity) in freshly cast components before final machining.

  • Tooling and Mold Repair: TIG welding repair of worn or damaged aluminum molds and casting tooling used in production.

  • Pump and Valve Housings: Repairing pressurized cast components in industrial fluid handling systems.

FAQ

  • Q: Why are Al-Si fillers (4XXX) required for castings?A: Most aluminum castings are Al-Si alloys. The matching high Si content in the filler provides the high fluidity needed to fill the complex crack geometries and ensures the weld solidifies quickly with a narrow freezing range, which is key to crack mitigation.
  • Q: Can I use ER5356 for casting repair?A: ER5356 is strongly discouraged for most castings. It is highly susceptible to severe solidification cracking when mixed with the high Si content of the casting, leading to repair failure.
  • Q: What is the risk of post-weld heat treatment (PWHT) on casting repairs?A: Castings often rely on PWHT for final strength. The Si in the filler can lead to less effective heat treatment response compared to the original casting alloy. The newer Al-Mg-Si alloy, ER4943, is sometimes used as a substitute for 4043 when some PWHT strength recovery is desired.

Advantages and Core Features

  • Superior Crack Resistance: The high Si content creates a narrow freezing range, preventing the formation of liquid films that cause hot tearing in the stressed cast metal.

  • Excellent Flow and Wetting: The fluidity allows the filler to penetrate deeply into complex internal cracks and porosity areas for a complete repair.

  • Tolerance for Contamination: More forgiving of residual oils and surface contamination often present in older, worn castings.

  • Low Melting Point: Reduces the overall heat input required, minimizing the risk of distortion and further cracking of the complex cast structure.

Material Selection Guide

For general casting repair (cracks, porosity, wear), ER4043 is the universal default. For high-integrity or high-temperature casting repair where maximum flow and minimum crack risk is needed, ER4047 (12% Si) is preferred. Always use TIG rods for manual repair to provide precise heat control.

About Us

Coming From China, Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is China Aluminium Filler Metal for Casting Repair Manufacturers and Wholesale Aluminium Filler Metal for Casting Repair 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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