Aluminum ER2519
ASTM AWS A5.10 ER2519
ER2519 is an Al-Cu (2000 series) weld filler classified under AWS A5.10, developed to match armor-grade 2519 plate and to give better weld and ballistic toughness than ER2319.
Reference datasheet — ER2519 is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the AW condition
ER2519 tempers and conditions
ER2519 is supplied in 3 conditions, soft to hard. AW is the default FabDigit quotes; the values on this page are for it.
Compare all 3 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
AWDefault As-welded deposit | Use the as-deposited weld metal condition when 2519/2219 armour plate receives no post-weld heat treatment; expect 165 MPa yield, 290 MPa tensile and limited corrosion resistance. | 165 | 290 | 7 | 80 HB | 29 % IACS |
as welded then post-weld artificially aged (~165 °C) | Choose post-weld artificial ageing near 165 °C without re-solutionising for large armour structures: yield rises to 235 MPa with low distortion risk, while elongation falls to 5%. | 235 | 340 | 5 | 100 HB | 32 % IACS |
Post-weld solution heat treated and artificially aged | Pick full post-weld solution treatment, quench and ageing on small parts to reach 275 MPa yield and 400 MPa tensile close to the base metal, accepting distortion and residual stress. | 275 | 400 | 6 | 115 HB | 30 % IACS |
Supply forms, finishes and certifications
Ways ER2519 is supplied — form, process route, surface or paperwork — without a datasheet of their own. The property values above apply.
| Option | What it is | Type |
|---|---|---|
WIRE-H | Wire/Rod | Supply form |
What is ER2519?
ER2519 is an Al-Cu (2000 series) weld filler classified under AWS A5.10, developed to match armor-grade 2519 plate and to give better weld and ballistic toughness than ER2319. It is supplied as cold-drawn spooled wire and straight cut rod for GMAW and GTAW of military vehicle hulls and structural weldments. As-welded deposits run about 165 MPa yield and 290 MPa tensile with 7 % elongation; corrosion resistance is low for the Al-Cu chemistry, so a painted or conversion-coated system is required and service is limited to about 150 °C. ER2319 is the usual alternative where matching 2519 chemistry is not specified. ER2519 has a density of 2.82 g/cm³ (0.102 lb/in³), heavier than 89% of aluminum grades. It melts at 543°C (1,009 °F). ER2519 has a yield strength of 165 MPa (23.9 ksi) and a tensile strength of 290 MPa (42.1 ksi) — weaker than 58% of aluminum grades. Elongation at break is 7% and the elastic modulus is 73 GPa (10.6 Msi).
What is ER2519 used for?
- Armored vehicle hull weldments
- Military vehicle structural welds
- 2519 armor plate butt and fillet joints
- Turret and hatch surround structures
- Battle-damage repair of armor structures
- Amphibious vehicle hull sections
Limitations
- Needs corrosion protection — 35/100, worse than 85% of aluminum grades
- Low electrical conductivity — 29 % IACS, worse than 78% of aluminum grades
- Hard to polish — 45/100, worse than 76% of aluminum grades
ER2519 properties
Typical room-temperature values for ER2519-AW; bars are the position among aluminum grades.
Physical3
ER2519 has a density of 2.82 g/cm³ (0.102 lb/in³), heavier than 89% of aluminum grades. It melts at 543°C (1,009 °F).
Mechanical12
ER2519 has a yield strength of 165 MPa (23.9 ksi) and a tensile strength of 290 MPa (42.1 ksi) — weaker than 58% of aluminum grades. Elongation at break is 7% and the elastic modulus is 73 GPa (10.6 Msi).
Thermal6
ER2519 is rated for continuous service to 150°C (302 °F). It conducts heat at 125 W/m·K (72.2 BTU/hr·ft·°F), worse than 72% of aluminum grades. Thermal expansion is 22.3 µm/m·K (12.4 µin/in·°F).
Electrical3
ER2519 conducts electricity at 29 % IACS, worse than 78% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is fair (35/100), worse than 85% of aluminum grades.
Sustainability4
Producing a kilogram of ER2519 takes about 205 MJ of energy and emits 13 kg of CO₂ — more than 76% of aluminum grades. Typical recycled content is 8%.
Manufacturability8
ER2519's machinability is good (65/100, better than 62% of aluminum grades); weldability good (65/100); formability fair (45/100).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the aluminum family
Yield strength against density for every aluminum grade FabDigit runs. ER2519 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with ER2519
Is ER2519 easy to machine?
Weld beads cut well with sharp, high-helix-angle tools at high speed; watch for local hard spots and burring caused by Cu-bearing intermetallic phases.
Can ER2519 be welded?
Use GMAW/GTAW with pure Ar or Ar-He shielding, strip oxide film and remove oil thoroughly, hold interpass temperature below 150 °C and keep heat input low to suppress hot cracking and HAZ softening.
Can ER2519 be formed, bent or molded?
Supplied as cold-drawn spooled wire or straight rod. As-welded ductility is limited, so avoid heavy cold forming of the weld zone.
ER2519 chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| Cuprimary strengthening element | 5.3 – 6.4 | 5.9 |
| Mn | 0.1 – 0.5 | 0.3 |
| Mghigher than ER2319, raises strength and toughness | 0.05 – 0.4 | 0.2 |
| Zrrefines weld metal grain structure | 0.1 – 0.25 | 0.17 |
| V | 0.05 – 0.15 | 0.1 |
| Tigrain refiner | 0.02 – 0.1 | 0.06 |
| Feimpurity limit | ≤ 0.3 | |
| Siimpurity limit | ≤ 0.25 | |
| Znimpurity limit | ≤ 0.1 | |
| Others (each) | ≤ 0.05 | |
| Others (total) | ≤ 0.15 | |
| Al | balance |
What surface finishes work on ER2519?
Anodizing produces a dark film with poor corrosion resistance; standard practice is chromate or chrome-free chemical conversion coating plus epoxy primer and a CARC topcoat per military paint systems.
Surface treatments FabDigit runs on aluminum parts — pick them in the quote configurator or call them out on the drawing. Each links to its datasheet in the surface-finish library (thickness, specs, call-out, material verdicts).
Organic Coating
Equivalent designations
Standards and trade names that resolve to Aluminum ER2519 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- ASTM
- AWS A5.10 ER2519
- Other
- 2519
How much does ER2519 cost?
ER2519 is a high-cost aluminum ($$$$), pricier than about 78% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
ER2519 — frequently asked
What is ER2519 used for?
ER2519 is typically used for armored vehicle hull weldments, military vehicle structural welds, 2519 armor plate butt and fillet joints, turret and hatch surround structures, battle-damage repair of armor structures and amphibious vehicle hull sections. In short: armor-grade 2519 match; tougher than ER2319; al-Cu military filler.
What is the yield strength of ER2519?
ER2519 has a typical yield strength of 165 MPa (23.9 ksi) and a tensile strength of 290 MPa (42.1 ksi) — weaker than 58% of aluminum grades. Strength varies by condition: see the 3 listed tempers.
Is ER2519 easy to machine?
Reasonably — machinability is rated good (65/100, better than 62% of aluminum grades). Weld beads cut well with sharp, high-helix-angle tools at high speed; watch for local hard spots and burring caused by Cu-bearing intermetallic phases.
Can ER2519 be welded?
Yes — weldability is rated good (65/100). Use GMAW/GTAW with pure Ar or Ar-He shielding, strip oxide film and remove oil thoroughly, hold interpass temperature below 150 °C and keep heat input low to suppress hot cracking and HAZ softening.
What surface finishes work on ER2519?
Anodizing produces a dark film with poor corrosion resistance; standard practice is chromate or chrome-free chemical conversion coating plus epoxy primer and a CARC topcoat per military paint systems.
Can ER2519 be formed, bent or molded?
Supplied as cold-drawn spooled wire or straight rod. As-welded ductility is limited, so avoid heavy cold forming of the weld zone.
What is the maximum service temperature of ER2519?
ER2519 is rated for continuous use to about 150°C (302 °F). Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between ER2519-AW and ER2519 PWHT-T6?
AW is the default condition — use the as-deposited weld metal condition when 2519/2219 armour plate receives no post-weld heat treatment; expect 165 MPa yield, 290 MPa tensile and limited corrosion resistance. PWHT-T6: pick full post-weld solution treatment, quench and ageing on small parts to reach 275 MPa yield and 400 MPa tensile close to the base metal, accepting distortion and residual stress. Yield strength is 165 MPa in AW versus 275 MPa in PWHT-T6.
How much does ER2519 cost?
ER2519 is a high-cost aluminum ($$$$), pricier than about 78% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- AWS A5.10/A5.10M — Bare Aluminum and Aluminum-Alloy Welding Electrodes and Rods — AWS (2021)
- International Alloy Designations and Chemical Composition Limits for Wrought Aluminum (Teal Sheets) — The Aluminum Association (2018)
- ASM Handbook Vol.2 — Properties and Selection: Nonferrous Alloys — ASM International (1990)
- ASM Handbook Vol.6 — Welding, Brazing and Soldering (Aluminum Alloys) — ASM International (1993)
- MMPDS — Metallic Materials Properties Development and Standardization (2519 data) — Battelle/FAA (2022)
- Aluminum filler metal datasheets (ER2319/ER2519) — Lincoln Electric / ESAB / Hobart (2023)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.