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Aluminum Wire for High Strength 7XXX Alloys

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Product Description

Specialized aluminum filler metals required for welding 7XXX series base metals (Al-Zn-Mg alloys, e.g., 7005, 7039), which are notoriously difficult to weld due to their high susceptibility to hot cracking and post-weld strength loss. The filler is chosen to chemically bridge the high Zn and Mg content, typically a high-Magnesium alloy like ER5556 or a high-Magnesium/Manganese filler, to successfully mitigate solidification cracking, though post-weld heat treatment may still be required to maximize strength recovery.

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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

7XXX series aluminum alloys offer some of the highest strength-to-weight ratios but pose a severe metallurgical challenge for welding due to their large solidification freezing range. This makes them highly prone to hot tearing (solidification cracking). We provide the necessary consumables and technical guidance to overcome this challenge. Our recommended fillers (ER5556, etc.) contain specific alloying elements that move the weld deposit chemistry out of the critical hot-cracking zone, ensuring a structurally sound weld, primarily used in defense, rail, and heavy transportation sectors.

Specification

Base Metal Focus7XXX Series (Al-Zn-Mg, e.g., 7005, 7039)
Filler Alloy FocusER5556, ER5183 (High Mg/Mn content)
Key ChallengeHigh susceptibility to Solidification Cracking (Hot Tearing)
Solution MechanismShifting the weld pool chemistry to minimize the solidification freezing range
Post-Weld TreatmentOften requires an artificial aging treatment (e.g., T6 or T7) for full strength recovery

Applications and Solutions

  • Defense and Armor Plating: Welding high-strength 7039 and similar alloys for military vehicle structures and ballistic protection.

  • High-Speed Rail Carriages: Structural components made from 7005 where high strength and fatigue performance are necessary.

  • Heavy Equipment Frames: Load-bearing structural members in cranes, heavy-duty trailers, and construction equipment.

  • Structural Repair: Repair of damaged components made from 7XXX series alloys where base metal strength must be maintained as much as possible.

FAQ

  • Q: Why are 7XXX alloys prone to cracking during welding?A: The combination of zinc (Zn) and magnesium (Mg) creates a wide freezing range during solidification. This leaves the partially solidified weld metal weak and susceptible to tearing under the residual stress of shrinkage (hot cracking).
  • Q: Can I use ER4043 to weld 7XXX alloys?A: ER4043 (Al-Si) is strongly discouraged. It reacts poorly with the high Zn and Mg content, forming brittle Mg2​Si and other intermetallic phases that severely compromise the strength and ductility of the weld. Use high-Mg fillers like ER5556.
  • Q: What is the main drawback of welding 7XXX alloys?A: Even with the correct filler, the Heat-Affected Zone (HAZ) adjacent to the weld often experiences significant strength loss (softening), which must often be recovered through a subsequent post-weld heat treatment (PWHT) cycle.

Advantages and Core Features

  • Maximized Crack Resistance: The high Mg and Mn content is specifically designed to tolerate the challenging chemistry of the 7XXX base metals, mitigating hot cracking.

  • High Strength Recovery: ER5556 and similar fillers yield a strong weld deposit that responds well to post-weld artificial aging/precipitation hardening treatments.

  • Improved Fatigue Life: The crack-free, strong weld deposit ensures high fatigue resistance in dynamically loaded structures common in rail and defense.

  • Code Compliance: Suitable for 7XXX welding procedures that require the final weldment to meet demanding mechanical property minimums.

Material Selection Guide

For welding high-strength 7XXX base metals (e.g., 7005, 7039), the best choice is ER5556. If the application permits, ER5183 is an acceptable alternative but offers slightly less strength and stabilization. Always consult the specific base metal alloy and required PWHT, as welding 7XXX without proper planning will result in catastrophic failure.

About Us

Coming From China, Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is China Aluminum Wire for High Strength 7XXX Alloys Manufacturers and Wholesale Aluminum Wire for High Strength 7XXX Alloys 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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