Aluminum ER4010
ASTM AWS A5.10 ER4010
ER4010 is an Al-Si-Mg filler under AWS A5.10 with a chemistry matched to 356/A356/357 sand and permanent-mould castings, giving good weld-pool fluidity and crack resistance.
Reference datasheet — ER4010 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
ER4010 tempers and conditions
ER4010 is supplied in 5 conditions, soft to hard. AW is the default FabDigit quotes; the values on this page are for it.
Compare all 5 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
AWDefault As-welded deposit | Default condition for repair welds that will not be re-heat-treated; moderate strength, good ductility and crack resistance. | 95 | 180 | 5 | 55 HB | 39 % IACS |
Solution heat treated and naturally aged | Pick when the repaired casting is solution treated but must stay ductile for straightening before final ageing. | 125 | 230 | 10 | 60 HB | 36 % IACS |
Cooled from hot working and artificially aged | Low-distortion option: age only (≈155–170 °C) to recover some strength when full solution treatment would warp the casting. | 140 | 200 | 4 | 65 HB | 40 % IACS |
Solution heat treated and overaged (stabilized) | Use where dimensional stability and toughness matter more than peak strength, e.g. hot-running housings. | 195 | 235 | 6 | 70 HB | 42 % IACS |
Solution heat treated and artificially aged | Standard choice for structural casting repairs: weld metal responds like A356-T6 and nearly matches base-metal strength. | 215 | 285 | 5 | 80 HB | 39 % IACS |
Supply forms, finishes and certifications
Ways ER4010 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 | Bare filler rod / spooled wire, as supplied | Supply form |
What is ER4010?
ER4010 is an Al-Si-Mg filler under AWS A5.10 with a chemistry matched to 356/A356/357 sand and permanent-mould castings, giving good weld-pool fluidity and crack resistance. It is used for casting repair and for joining cast parts that may be re-heat-treated, and is supplied as wire and rod with AW, T4, T5, T6 and T7 conditions on file. As-welded strength is modest at about 95 MPa yield, 180 MPa tensile and 5 % elongation, and service is limited to roughly 150 °C. ER4009 is the closer match for Cu-bearing C355-type castings. ER4010 has a density of 2.67 g/cm³ (0.0965 lb/in³), lighter than 78% of aluminum grades. It melts at 557°C (1,035 °F). ER4010 has a yield strength of 95 MPa (13.8 ksi) and a tensile strength of 180 MPa (26.1 ksi) — weaker than 86% of aluminum grades. Elongation at break is 5% and the elastic modulus is 72 GPa (10.4 Msi).
What is ER4010 used for?
- Cast aluminum repair
- A356 casting welds
- Engine and gearbox housing repair
- Permanent-mould casting rework
- Cast pump and valve body repair
- Foundry upgrading of sand castings
Advantages
- Readily welded — 92/100, better than 95% of aluminum grades
Limitations
- Low strength — 95 MPa (13.8 ksi), worse than 86% of aluminum grades
- Hard to polish — 45/100, worse than 76% of aluminum grades
ER4010 properties
Typical room-temperature values for ER4010-AW; bars are the position among aluminum grades.
Physical3
ER4010 has a density of 2.67 g/cm³ (0.0965 lb/in³), lighter than 78% of aluminum grades. It melts at 557°C (1,035 °F).
Mechanical12
ER4010 has a yield strength of 95 MPa (13.8 ksi) and a tensile strength of 180 MPa (26.1 ksi) — weaker than 86% of aluminum grades. Elongation at break is 5% and the elastic modulus is 72 GPa (10.4 Msi).
Thermal6
ER4010 is rated for continuous service to 150°C (302 °F). It conducts heat at 152 W/m·K (87.8 BTU/hr·ft·°F), better than 66% of aluminum grades. Thermal expansion is 21.5 µm/m·K (11.9 µin/in·°F).
Electrical3
ER4010 conducts electricity at 39 % IACS, better than 65% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is good (62/100), better than 67% of aluminum grades.
Sustainability4
Producing a kilogram of ER4010 takes about 200 MJ of energy and emits 12.5 kg of CO₂ — less than 60% of aluminum grades. Typical recycled content is 20%.
Manufacturability8
ER4010's machinability is good (55/100, worse than 59% of aluminum grades); weldability excellent (92/100); 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. ER4010 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with ER4010
Is ER4010 easy to machine?
Weld beads machine easily with sharp polished-flute carbide and high speed, but the eutectic silicon is abrasive — expect tool wear similar to A356 and use flood coolant to avoid smearing.
Can ER4010 be welded?
Designed for GTAW/GMAW repair of 356/A356/357 castings; preheat 120–200 °C on heavy sections, keep interpass below ~200 °C, use AC or He-mixed shielding gas and clean oxide thoroughly to avoid porosity from the Mg-bearing pool.
Can ER4010 be formed, bent or molded?
Not a wrought product form — the alloy is supplied only as rod/wire; deposited metal has cast-structure ductility and should not be cold formed or peened heavily.
ER4010 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 | 6.5 – 7.5 | 7 |
| Mgheat-treatable strengthening addition | 0.3 – 0.45 | 0.37 |
| Feimpurity limit | ≤ 0.2 | |
| Cu | ≤ 0.2 | |
| Mn | ≤ 0.1 | |
| Zn | ≤ 0.1 | |
| Tigrain refiner | ≤ 0.2 | |
| Berestricted for fume safety | ≤ 3×10⁻⁴ | |
| Others (each) | ≤ 0.05 | |
| Others (total) | ≤ 0.15 | |
| Al | balance |
What surface finishes work on ER4010?
Takes chromate/chemical conversion coating and paint well; anodizing turns dark grey and rarely colour-matches the parent casting, so mask or hand-blend repairs before decorative finishing.
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 ER4010 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- ASTM
- AWS A5.10 ER4010
- Other
- 4010
How much does ER4010 cost?
ER4010 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.
ER4010 — frequently asked
What is ER4010 used for?
ER4010 is typically used for cast aluminum repair, A356 casting welds, engine and gearbox housing repair, permanent-mould casting rework, cast pump and valve body repair and foundry upgrading of sand castings. In short: A356 casting-matched filler; good fluidity, crack resistant; heat-treatable weld deposit.
What is the yield strength of ER4010?
ER4010 has a typical yield strength of 95 MPa (13.8 ksi) and a tensile strength of 180 MPa (26.1 ksi) — weaker than 86% of aluminum grades. Strength varies by condition: see the 5 listed tempers.
Is ER4010 easy to machine?
Reasonably — machinability is rated good (55/100, worse than 59% of aluminum grades). Weld beads machine easily with sharp polished-flute carbide and high speed, but the eutectic silicon is abrasive — expect tool wear similar to A356 and use flood coolant to avoid smearing.
Can ER4010 be welded?
Yes — weldability is rated excellent (92/100). Designed for GTAW/GMAW repair of 356/A356/357 castings; preheat 120–200 °C on heavy sections, keep interpass below ~200 °C, use AC or He-mixed shielding gas and clean oxide thoroughly to avoid porosity from the Mg-bearing pool.
What surface finishes work on ER4010?
Takes chromate/chemical conversion coating and paint well; anodizing turns dark grey and rarely colour-matches the parent casting, so mask or hand-blend repairs before decorative finishing.
Can ER4010 be formed, bent or molded?
Not a wrought product form — the alloy is supplied only as rod/wire; deposited metal has cast-structure ductility and should not be cold formed or peened heavily.
What is the maximum service temperature of ER4010?
ER4010 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 ER4010-AW and ER4010-T6?
AW is the default condition — default condition for repair welds that will not be re-heat-treated; moderate strength, good ductility and crack resistance. T6: standard choice for structural casting repairs: weld metal responds like A356-T6 and nearly matches base-metal strength. Yield strength is 95 MPa in AW versus 215 MPa in T6.
How much does ER4010 cost?
ER4010 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 — Specification for Bare Aluminum and Aluminum-Alloy Welding Electrodes and Rods — American Welding Society (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 and Special-Purpose Materials — ASM International (1990)
- Welding Handbook Vol. 4 — Materials and Applications (Aluminum) — American Welding Society (2011)
- Aluminium filler metal selection and weld-metal property data — Filler-metal producers (Lincoln/ESAB/Indalco class data) (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.