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High-Temperature Service Aluminum Wire

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Product Description

Aluminum filler metals specifically formulated for components operating at sustained elevated temperatures (typically >150∘C) where creep resistance and stability are essential. Alloys like ER4043 and the heat-treatable ER4943 are preferred for their stability and resistance to softening at temperature, unlike high-Mg alloys (5XXX) which can become susceptible to Stress Corrosion Cracking (SCC) when exposed to heat. The material is manufactured to minimize impurity levels which could accelerate the formation of brittle phases at high temperatures.

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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

While aluminum is not typically considered a high-temperature metal, its use in engine components, turbo machinery, and complex heat exchangers requires welds that maintain structural integrity and creep resistance far above ambient temperature. We provide consumables that minimize the post-weld reduction in strength and resist metallurgical changes (like precipitation or over-aging) caused by continuous high-temperature service. This is critical for applications where the component must survive thousands of hours under stress at peak operating temperatures.

Specification

Alloy FocusER4043, ER4943, specialized 2XXX alloys (for aerospace)
Service TemperatureSustained operation typically above 150∘C (300∘F)
Key PropertyResistance to Creep and Metallurgical Softening (Over-Aging)
Prohibited AlloysER5XXX series (due to high-temperature SCC risk)
Test FocusTensile/Yield Strength retention after prolonged thermal exposure

Applications and Solutions

  • Automotive Engine Components: Welding intake manifolds, turbo piping, and cylinder heads (often 3XX.X cast alloys) exposed to hot exhaust gases.

  • High-Temperature Heat Exchangers: Aluminum modules in industrial dryers, kilns, and thermal processing equipment.

  • Aerospace Ducts and Housings: Components near engine bays or hydraulic lines subject to sustained thermal loading.

  • Repair of Castings: Repairing defects in cast components that will be subject to subsequent high-temperature heat treatment or service.

FAQ

  • Q: Why are 5XXX fillers dangerous in high-temperature service?A: When 5XXX alloys (high Mg) are held above ∼65∘C for extended periods, the β-phase (Al3​Mg2​) precipitates form at the grain boundaries, making the material highly susceptible to severe Stress Corrosion Cracking (SCC).
  • Q: Which filler retains the highest strength at elevated temperatures?A: Specialized heat-treatable aerospace fillers like ER2319 or the common ER4943 (Al-Si-Mg) are designed to retain the highest strength when properly aged for high-temperature service. ER4043 is used for stability, not maximum strength.
  • Q: Does high-temperature service require a specific base metal?A: Yes. Base metals like 6061-T6 are usually unsuitable. Specialized alloys like 6061-T651 (T6 temper with over-aging treatment) or cast alloys like A357 are often used for their inherent high-temperature stability.

Advantages and Core Features

  • Creep Resistance: The Al-Si matrix and certain heat-treatable fillers maintain structural integrity and resist plastic deformation under long-term high temperature and stress.

  • Microstructure Stability: Chemistry is formulated to resist the severe loss of strength (over-aging) that can occur in susceptible aluminum alloys at elevated temperatures.

  • SCC Mitigation: Eliminates the high-Magnesium content of 5XXX alloys, removing the primary risk factor for stress corrosion cracking in high-temperature service.

  • Process Compatibility: The high fluidity of 4XXX alloys ensures sound fusion in the repair of complex, thick-walled cast components common in high-temperature systems.

Material Selection Guide

For general high-temperature service where stability is key, specify ER4043. For applications requiring the highest strength retention after thermal exposure, specify the heat-treatable ER4943 or specialty 2XXX fillers. Absolutely prohibit the use of any 5XXX series filler when the service temperature exceeds 65∘C for prolonged periods.

About Us

Coming From China, Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is China High-Temperature Service Aluminum Wire Manufacturers and Wholesale High-Temperature Service Aluminum 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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