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Low Porosity Aluminum Welding Filler

-- Steady & Reliable Manufacturer --

Product Description

Aluminum filler metals engineered with a multi-pronged approach to minimize internal and surface porosity in the final weld deposit. This involves three critical stages: 1) Clean Billet Source (low hydrogen H2​ content); 2) Multi-Stage Mechanical Shaving (to remove surface oxides); and 3) Hermetic Packaging (to prevent moisture ingress). The resulting wire is suitable for X-ray quality structural welds where the volumetric porosity percentage must be maintained below a strict limit (e.g., <0.5%), as required by ASME or API codes.

DB Certification CE Certification ABS Certification DNV Certification CCS Certification

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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

Porosity—tiny trapped gas pockets—is the most common defect in aluminum welding and severely compromises the fatigue life and static strength of a weld. Our low porosity filler line is our premium commitment to weld integrity. We control the hydrogen content from the raw billet stage via vacuum degassing, and continuously remove surface oxides that carry moisture into the weld pool. By providing an ultra-clean wire, we drastically simplify the fabricator's job, ensuring that even under less-than-perfect shop conditions, the resulting weld meets the most stringent Non-Destructive Testing (NDT) requirements.

Specification

Key Process ControlMechanical Shaving (Die Shaving) and Vacuum Degassing of Billet
Porosity MetricGuaranteed volumetric porosity <0.5% in standardized weld pads
Primary SourceHydrogen (absorbed moisture and residual gas in billet)
Packaging MethodHermetically sealed, foil-laminate or metalized bags/drums
Test ComplianceDesigned to pass AWS D1.2, API 1104, and ASME Section IX NDT standards

Applications and Solutions

  • Pressure Vessels and Pipelines: Mandated for components built to ASME Boiler and Pressure Vessel Codes where X-ray quality welds are compulsory.

  • Aerospace and Defense Structures: Critical load-bearing joints requiring sub-0.5% volumetric porosity for fracture toughness and fatigue performance.

  • Subsea and Offshore Fabrication: Welding components designed for continuous submerged service where high structural integrity is essential.

  • High-Cycle Fatigue Applications: Any structure subject to constant stress reversal where internal defects must be eliminated to prevent crack initiation.

FAQ

  • Q: What is the main cause of porosity in aluminum welding?A: Hydrogen. Aluminum readily dissolves hydrogen gas in its liquid state. As the weld pool solidifies, the solubility drops drastically, and the hydrogen precipitates out, becoming trapped as spherical pores within the solid metal. The sources are primarily moisture (from oxides, air) or residual gas in the base metal/filler.
  • Q: Does a smooth weld bead mean the weld is free of porosity?A: No. Surface appearance relates to arc stability and technique. Internal porosity is only detectable through volumetric Non-Destructive Testing (NDT) methods like X-ray radiography or ultrasonic testing.
  • Q: How does mechanical shaving reduce porosity?A: Mechanical shaving removes the outer layer of the aluminum wire, which contains the majority of the surface oxides and adsorbed moisture. This prevents these contaminants from entering the weld pool and generating hydrogen gas.

Advantages and Core Features

  • Maximum Weld Integrity: Directly correlates with increased static strength, fatigue life, and fracture toughness by eliminating internal stress concentrators.

  • Highest NDT Pass Rate: Guarantees a significant reduction in inspection failures and costly rework (grinding out and re-welding defective joints).

  • Superior Feedability: The aggressive shaving process creates a highly uniform, smooth surface, minimizing friction and optimizing wire feeding.

  • Contaminant Exclusion: The final hermetic seal prevents the absorption of ambient moisture, preserving the wire's purity from our facility to the customer's torch.

Material Selection Guide

For any X-ray critical or life-critical application, specify a filler metal with a guaranteed low porosity certification. This is essential for alloys like ER5183 and ER5556 used in structural work. Always check the packaging—if it is not hermetically sealed or supplied with a desiccant, its low-porosity status may be compromised.

About Us

Coming From China, Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is China Low Porosity Aluminum Welding Filler Manufacturers and Wholesale Low Porosity Aluminum Welding Filler 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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