Web Menu

Product Search

Language

Share

Aluminum Wire for High Heat Input Welding

-- Steady & Reliable Manufacturer --

Product Description

Aluminum filler metals optimized for processes utilizing high amperage and low travel speed (e.g., submerged arc welding, tandem MIG, or high-current spray transfer) that generate extreme thermal energy in the weld zone. These materials possess enhanced chemical stability (e.g., specific Manganese and Chromium content in 5XXX alloys) to manage the enlarged heat-affected zone (HAZ) and prevent micro-fissuring or excessive grain growth, which can compromise the strength and fatigue life of the final component.

DB Certification CE Certification ABS Certification DNV Certification CCS Certification

Related Products

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

High heat input welding is often necessary for achieving the required penetration and deposition rate in thick-plate fabrication. However, it places immense stress on the filler metal and base metal integrity. Our wire is engineered to resist metallurgical degradation under these conditions. The alloy composition includes elements that pin grain boundaries, stabilizing the microstructure and minimizing the detrimental effects of slow cooling, providing a solution that allows fabricators to maximize efficiency without sacrificing the weld's structural performance.

Specification

Alloy FocusER5183, ER5556 (high strength, micro-stabilized)
Key AdditivesChromium (Cr) and Manganese (Mn) for microstructure stabilization
Required PropertiesHigh resistance to hot tearing and weld metal softening in the HAZ
Typical Current Range400A to 600A (GMAW-P and Spray Transfer)
Weld Profile FocusOptimized for deep penetration and minimal fusion boundary irregularities

Applications and Solutions

  • Automated Plate Welding: Used in mechanized systems for joining large, thick aluminum plates in shipbuilding and infrastructure projects.

  • Root and Hot Passes: Specifically utilized for high-amperage root passes that demand deep, consistent fusion and minimal defects.

  • Large Circumferential Seams: Automated welding of massive storage tanks or pressure vessels where the continuous, high-amperage welding process generates significant residual heat.

  • High-Speed Tandem MIG: Supplying material for tandem or twin-arc systems that combine two high-current arcs to achieve maximum deposition.

FAQ

  • Q: Does high heat input welding increase the risk of solidification cracking?A: Yes, especially in some alloys. However, our materials are selected (e.g., ER5183) and chemically stabilized to resist hot tearing even under the slow cooling conditions typical of high heat input processes.
  • Q: How do Chromium and Manganese additions help in high heat input?A: Chromium (Cr) and Manganese (Mn) form fine dispersoids (Al12​Mg2​Cr or Al6​Mn) which pin the aluminum grain boundaries. This prevents excessive grain growth (coarsening) in the weld and HAZ, which is key to maintaining strength and toughness.
  • Q: Is there a maximum interpass temperature for high heat input welding?A: Yes. For high-strength 5XXX alloys, the maximum interpass temperature must be strictly controlled, typically staying below 93∘C (200∘F) to prevent the formation of precipitates that cause stress corrosion cracking (SCC) risk.

Advantages and Core Features

  • HAZ Stability: Specific trace element additions stabilize the grain structure in the heat-affected zone, mitigating the severe grain coarsening associated with high heat input.

  • Cracking Resilience: The material composition is optimized to survive the large volume shrinkage and high residual stress environment created by large, slow-cooling weld pools.

  • Consistent Fusion: Enhanced electrical conductivity ensures a powerful, focused arc that cuts through heavy oxides, achieving consistent fusion even in deep joints.

  • Reduced Rework: The stable chemistry and superior flow minimize the occurrence of lack of fusion and internal cracking, reducing the need for costly defect grinding.

Material Selection Guide

For high heat input on thick sections, ER5183 or the stronger ER5556 (when structural demands are high) is the correct choice. Due to the high thermal stress, avoid ER4043 unless necessary for 6XXX base metals, and even then, use with caution. Always verify that the wire is supplied in a large diameter (1.6mm and up) and in a format (bulk drum) that supports continuous welding.

About Us

Coming From China, Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is China Aluminum Wire for High Heat Input Welding Manufacturers and Wholesale Aluminum Wire for High Heat Input Welding 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.
GET IN TOUCH

Send Us a Message?

Related Products

Discover our complete range of welding materials

⚡ Aluminum Wire for High-Purity Electrical Conductors ⚡ Aluminum Alloy Wire for Heat Exchanger ⚡ Welding Wire for High-Strength 7XXX Alloys ⚡ Aluminum Wire for Friction Stir Welding (FSW) Tools ⚡ Aluminum Wire for High-Purity 5XXX Alloys ⚡ Aluminum Welding Wire for Marine Environments ⚡ Aluminum Wire for High Strength 7XXX Alloys ⚡ Aluminum Wire for Pulse MIG Welding ⚡ Aluminum Wire for High Purity Applications ⚡ Aluminum Wire for Thick Section Welding