Aluminum ER4009-AW (As-welded deposit)
Heat-treated state · default condition
ASTM AWS A5.10 ER4009
Default condition for field or in-service repair of castings where no furnace cycle is possible; moderate strength, low ductility.
Values for the AW condition
Other ER4009 tempers and conditions
ER4009 is listed in 4 conditions; see the grade overview at ER4009.
Compare all 4 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
AWDefaultThis page As-welded deposit | Default condition for field or in-service repair of castings where no furnace cycle is possible; moderate strength, low ductility. | 125 | 200 | 3 | 60 HB | 37 % IACS |
As fabricated | Pick this for the physical wire or rod itself (spool feedability, straightness, cut-length stiffness), not for joint design. | 150 | 215 | 6 | 65 HB | 38 % IACS |
Cooled from hot working and artificially aged | Use when the component cannot be re-solutionised (distortion/quench risk) but a low-temperature age (~155–170 °C) can recover part of the strength. | 170 | 235 | 2.5 | 72 HB | 39 % IACS |
Solution heat treated and artificially aged | The reason ER4009 exists — full C355-T6 cycle on the repaired casting gives weld metal strength close to the parent material. | 215 | 290 | 3 | 88 HB | 39 % IACS |
What is ER4009-AW?
ER4009-AW is ER4009 heat treated to AW — default condition for field or in-service repair of castings where no furnace cycle is possible; moderate strength, low ductility. ER4009-AW has a yield strength of 125 MPa (18.1 ksi) and a tensile strength of 200 MPa (29 ksi) — weaker than 75% of aluminum grades. Elongation at break is 3% and the elastic modulus is 71 GPa (10.3 Msi). ER4009-AW has a density of 2.71 g/cm³ (0.0979 lb/in³), heavier than 51% of aluminum grades. It melts at 546°C (1,015 °F).
Advantages
- Readily welded — 85/100, better than 79% of aluminum grades
Limitations
- Limited ductility — 3%, worse than 79% of aluminum grades
- Low strength — 125 MPa (18.1 ksi), worse than 75% of aluminum grades
ER4009-AW properties
Typical room-temperature values for ER4009-AW; 11 are specific to this condition. Other listed values are ER4009 reference data and may not represent this condition. Bars are the position among aluminum grades.
Physical3
ER4009-AW has a density of 2.71 g/cm³ (0.0979 lb/in³), heavier than 51% of aluminum grades. It melts at 546°C (1,015 °F).
Mechanical10
ER4009-AW has a yield strength of 125 MPa (18.1 ksi) and a tensile strength of 200 MPa (29 ksi) — weaker than 75% of aluminum grades. Elongation at break is 3% and the elastic modulus is 71 GPa (10.3 Msi).
Thermal6
ER4009-AW is rated for continuous service to 150°C (302 °F). It conducts heat at 145 W/m·K (83.8 BTU/hr·ft·°F), better than 53% of aluminum grades. Thermal expansion is 22.4 µm/m·K (12.4 µin/in·°F).
Electrical3
ER4009-AW conducts electricity at 37 % IACS, better than 58% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is fair (45/100), worse than 62% of aluminum grades.
Sustainability4
Producing a kilogram of ER4009-AW takes about 158 MJ of energy and emits 11.5 kg of CO₂ — less than 93% of aluminum grades. Typical recycled content is 10%.
Manufacturability8
ER4009-AW's machinability is good (60/100, worse than 51% of aluminum grades); weldability excellent (85/100); formability fair (45/100).
Common Calculations5
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with ER4009-AW
Is ER4009 easy to machine?
Weld deposits machine like C355 — sharp PCD or polished carbide tooling, high speed, flood coolant; the primary Si particles are abrasive to HSS.
Can ER4009 be welded?
Designed for GTAW/GMAW of C355/A356/A357 castings; preheat 100–150 °C on heavy sections, keep interpass low, and plan a full post-weld T6 (solution ~525 °C, quench, age) for rated strength.
Can ER4009 be formed, bent or molded?
Supplied only as drawn wire or cut rod — no forming application; keep wire clean and dry and re-clean oxidised surfaces before use to avoid weld porosity.
What surface finishes work on ER4009?
Grind/blend flush before anodizing; expect dark, mottled anodic films from the Si+Cu chemistry, so use chromic/hardcoat or paint rather than decorative colour anodize.
ER4009 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 |
|---|---|---|
| Si | 4.5 – 5.5 | 5 |
| Cu | 1 – 1.5 | 1.25 |
| Mg | 0.45 – 0.6 | 0.5 |
| Fe | ≤ 0.2 | — |
| Mn | ≤ 0.1 | — |
| Zn | ≤ 0.1 | — |
| Ti | ≤ 0.2 | — |
| Be | ≤ 3×10⁻⁴ | — |
| Others (each)max each | ≤ 0.05 | — |
| Others (total)max total | ≤ 0.15 | — |
| Alremainder; chemistry corresponds to C355.0 casting alloy | balance | — |
ER4009-AW — frequently asked
What is ER4009-AW used for?
ER4009-AW is typically used for A356/A357 casting repair, automotive cast wheel welds and cast housing repair. In short: casting-matched Al-Si-Mg filler; heat-treatable weld deposit; for C355/A356 repair.
What is the yield strength of ER4009-AW?
ER4009-AW has a typical yield strength of 125 MPa (18.1 ksi) and a tensile strength of 200 MPa (29 ksi) — weaker than 75% of aluminum grades. Strength varies by condition: see the 4 listed tempers.
Is ER4009-AW easy to machine?
Reasonably — machinability is rated good (60/100, worse than 51% of aluminum grades). Weld deposits machine like C355 — sharp PCD or polished carbide tooling, high speed, flood coolant; the primary Si particles are abrasive to HSS.
Can ER4009-AW be welded?
Yes — weldability is rated excellent (85/100). Designed for GTAW/GMAW of C355/A356/A357 castings; preheat 100–150 °C on heavy sections, keep interpass low, and plan a full post-weld T6 (solution ~525 °C, quench, age) for rated strength.
What surface finishes work on ER4009-AW?
Grind/blend flush before anodizing; expect dark, mottled anodic films from the Si+Cu chemistry, so use chromic/hardcoat or paint rather than decorative colour anodize.
Can ER4009-AW be formed, bent or molded?
Supplied only as drawn wire or cut rod — no forming application; keep wire clean and dry and re-clean oxidised surfaces before use to avoid weld porosity.
What is the maximum service temperature of ER4009-AW?
ER4009-AW 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 ER4009-AW and ER4009-T6?
AW is the default condition — default condition for field or in-service repair of castings where no furnace cycle is possible; moderate strength, low ductility. T6: the reason ER4009 exists — full C355-T6 cycle on the repaired casting gives weld metal strength close to the parent material. Yield strength is 125 MPa in AW versus 215 MPa in T6.
Sources
- AWS A5.10/A5.10M — Welding Consumables — Wire Electrodes, Wires and Rods for Welding of Aluminium and Aluminium Alloys — American Welding Society (2021)
- AMS 4189 / Aluminum Association Registration Record of Filler Alloys — SAE / The Aluminum Association (2018)
- ASM Handbook Vol.2 — Properties and Selection: Nonferrous Alloys (C355.0 data) — ASM International (1990)
- ASM Handbook Vol.6 — Welding, Brazing and Soldering (aluminium filler selection) — ASM International (1993)
- Aluminium filler metal selection and property guides — Lincoln Electric / ESAB / Indalco (2023)
Property data is compiled from published supplier and standards handbooks and normalised for comparison. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.