4043 is a 5% Silicon Aluminum filler metal which has excellent flowability and penetration characteristics, recommended for welding Aluminum alloys with maximun 2% alloys element and for Aluminum alloys containing up to 7% of Si, such as 2014,3003,3004, 5052, 6060,6061,6063 and 6082. Mainly used in chemicals, molds, furniture, storage boxes, containers and other industries.
ER4043 Silicon Aluminum Welding Wire is a common aluminum alloy welding filler material, which is widely used in aluminum alloy welding work. ER4043 welding wire is mainly composed of silicon (Si) and aluminum (Al), and is usually used for welding and repairing aluminum and aluminum alloys. It is widely used in ships, automobiles, aviation, construction, light industry and other fields that require aluminum alloy structures.
Main characteristics of ER4043 welding wire:
Alloy composition:
Mainly composed of aluminum and silicon alloy, the silicon content is generally between 4.5% and 6.0%, and the addition of silicon improves the fluidity and wettability during welding.
The addition of silicon can also reduce the solid solution temperature of the metal during welding, thereby reducing the tendency of thermal cracking during welding.
Welding performance:
ER4043 welding wire is suitable for AC and DC welding, and has good arc stability during welding.
The weld metal has good oxidation resistance and corrosion resistance, and is suitable for welding aluminum alloys and their materials.
The surface of the welded joint is smooth and flat, and the welding heat affected zone is small.
Advantages:
The weld metal has good compatibility with welding aids such as fluoride salts, and the welding slag is easy to remove during welding.
The molten pool produced by welding has good fluidity and smoother molding, which reduces unnecessary welding defects.
It has good adaptability in the welding process of various aluminum alloys.
Common specifications of ER4043 welding wire:
Diameter range: ER4043 welding wire usually has different diameter specifications, such as 0.8mm, 1.0mm, 1.2mm, 1.6mm, etc. The specific selection depends on the welding process, welding material thickness and welding current requirements.
Length: The length of the welding wire is usually between 1-5 meters, and the manufacturer can customize it according to customer needs.
Application scenarios of ER4043:
Aluminum alloy welding: ER4043 welding wire is suitable for welding aluminum alloys (such as aluminum-silicon alloy series) and is widely used in automobile manufacturing, aerospace and other fields.
Repair and repair: This welding wire is suitable for the repair of aluminum alloy parts, such as aluminum alloy frames, aluminum shells, etc. The welding process can repair common defects such as cracks and corrosion damage.
Pipeline welding: In pipeline welding, especially aluminum alloy pipelines that need to be protected from corrosion, ER4043 welding wire shows good welding performance and forming ability.
Light industrial manufacturing: Aluminum alloy structures used for the production and repair of light equipment, home appliance housings, vehicles and related parts.
Welding of aluminum structures: Such as the manufacture of hulls, car bodies, bridges and some large aluminum structures.
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Applicability analysis
Material matching: compatibility of ER4043 (containing 5% silicon) with common cast aluminum alloys (such as A356, ADC12), reducing the risk of thermal cracks.
Flowability advantage: Silicon element improves the fluidity of the molten pool and is suitable for filling irregular defects such as pores and shrinkage holes in castings.
Core challenges of repair
Risk of welding pores caused by the porosity of castings;
Softening problems in the heat-affected zone (HAZ);
Deformation or secondary cracking caused by residual stress.
1. Defect pretreatment
Cleaning: Use acetone or special solvent to remove oil stains and mechanically grind the oxide layer (avoid chemical cleaning residues).
Defect grooving: Bevel the pores/cracks (V-groove is recommended, angle 60°-70°) to expose fresh metal.
2. Welding parameter optimization
Parameter | Recommended Range | Notes |
---|---|---|
Shielding Gas | Pure Ar (99.99%) | Flow rate: 15-20 L/min |
Current Type | AC TIG or Pulsed MIG | AC removes oxide layer, pulsed mode reduces heat input |
Preheat Temperature | 150-250°C (for large castings) | Prevents rapid cooling cracks |
Interpass Temperature | ≤100°C | Avoids overheating and softening |
3. Welding skills
Hole filling strategy: segmented jump welding (2-3cm interval) to reduce local heat accumulation.
Arc closure treatment: current attenuation function to avoid arc crater cracks, add filler metal to fill if necessary.
Case 1: Engine cylinder block air hole repair
Problem: A356 cylinder block pouring air hole (diameter 3-5mm).
Solution: TIG welding + ER4043, preheating 200℃, low current (90-110A) layered cladding.
Result: X-ray detection shows no unfused, and the surface meets the standard after machining.
Case 2: Die casting mold crack repair
Challenge: ADC12 mold thermal fatigue crack (depth > 2mm).
Key points: Drilling crack stop holes at the end of the crack, MIG pulse welding (wire feeding speed 5m/min).
Stress relief:
Vibration aging or 250℃×2h annealing (select according to the purpose of the casting).
Detection method:
Visual/penetrant inspection: surface cracks;
X-ray/ultrasonic: internal defects;
Hardness test: The difference between HAZ and base material is ≤15HB for qualified.
Problem 1: Many pores in the weld
Check gas purity, workpiece humidity, and increase preheating temperature.
Problem 2: Poor post-weld processing
Control silicon segregation to avoid excessive heat input leading to coarse grains.