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Casting Repair Aluminum Filler Wire

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Intro

Aluminum filler metals specifically formulated to restore damaged or porous aluminum castings, providing post-weld color match and machinability.

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Introduction

Repairing aluminum castings—common in engine blocks, transmission cases, and pump housings—requires a filler metal that is metallurgically compatible with the cast alloy. Our casting repair wires, primarily Aluminum-Silicon alloys, are designed to minimize distortion during welding and achieve a weld deposit that mimics the base casting's color and hardness. This enables subsequent machining, grinding, and blending operations without noticeable aesthetic or structural differences.

Specification

Classification (AWS)ER4047 / ER4043
Key PropertyLow shrinkage and susceptibility to cracking
Base Metal CompatibilityA356, 319, 357 (common aluminum casting alloys)
Post-Weld FinishGood color match after anodizing or painting
Pre-Weld PreparationRequires thorough oil and contaminant removal

Applications

  • Repairing cracks, shrinkage, and porosity in cast aluminum engine blocks.

  • Restoring damaged molds and tooling made from cast aluminum.

  • Adding material to worn or mis-machined areas of aluminum castings.

  • Joining wrought aluminum components to cast aluminum structures.

FAQ

  • Q: Can these filler wires be used to repair unknown aluminum casting alloys?
  • A: While ER4043 and ER4047 are versatile, for best results and to minimize cracking, the base metal must be identified. These wires work best on cast aluminum-silicon alloys and are not recommended for high-zinc or high-magnesium castings.
  • Q: Is preheating necessary when repairing aluminum castings with these wires?
  • A: Preheating is highly recommended for all aluminum casting repairs, especially thick sections or complex geometries, to reduce thermal gradients and prevent further cracking due to high residual stresses.

Advantages

  • Improved Machinability: The weld metal's hardness is controlled to allow for easy finishing operations such as drilling, tapping, and milling after repair.

  • High Resistance to Cracking: The added Silicon content effectively manages solidification shrinkage stresses, significantly reducing the likelihood of cracking in the weld zone.

  • Aesthetic Integration: Weld deposit chemistry is optimized for a close color match to common aluminum castings, minimizing visual defects after repair.

  • Versatility: Suitable for both TIG and MIG processes used in repair workshops and foundries.

Payment and Shipping

  • Inventory: Immediate availability of common sizes for fast turnaround on urgent repair material needs.

  • Customer Support: Technical assistance provided for selecting the optimal filler metal based on the specific cast alloy composition.

  • Packaging: Smaller spools and cut-length TIG rods are available, catering to job shop and repair center requirements.

About Us

Coming From China, Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is China Casting Repair Aluminum Filler Wire Manufacturers and Wholesale Casting Repair Aluminum Filler 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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