Aluminum ER4010-T4
Temper
ASTM AWS A5.10 ER4010
T4 = solution heat treated and naturally aged
Pick when the repaired casting is solution treated but must stay ductile for straightening before final ageing.
Values for the T4 condition
Other ER4010 tempers and conditions
ER4010 is listed in 5 conditions; see the grade overview at ER4010.
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 |
T4This page 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 |
What is ER4010-T4?
ER4010-T4 is ER4010 in the T4 temper — pick when the repaired casting is solution treated but must stay ductile for straightening before final ageing. ER4010-T4 has a yield strength of 125 MPa (18.1 ksi) and a tensile strength of 230 MPa (33.4 ksi) — weaker than 75% of aluminum grades. Elongation at break is 10% and the elastic modulus is 72 GPa (10.4 Msi). ER4010-T4 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). AW is the default condition FabDigit quotes; T4 is available on request or by drawing note.
Advantages
- Readily welded — 92/100, better than 95% of aluminum grades
Limitations
- Limited service temperature — 120°C (248 °F), worse than 79% of aluminum grades
- Hard to polish — 45/100, worse than 76% of aluminum grades
- Low strength — 125 MPa (18.1 ksi), worse than 75% of aluminum grades
ER4010-T4 properties
Typical room-temperature values for ER4010-T4; 21 are specific to this condition. Other listed values are ER4010 reference data and may not represent this condition. Bars are the position among aluminum grades.
Physical3
ER4010-T4 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-T4 has a yield strength of 125 MPa (18.1 ksi) and a tensile strength of 230 MPa (33.4 ksi) — weaker than 75% of aluminum grades. Elongation at break is 10% and the elastic modulus is 72 GPa (10.4 Msi).
Thermal6
ER4010-T4 is rated for continuous service to 120°C (248 °F). It conducts heat at 141 W/m·K (81.5 BTU/hr·ft·°F), better than 50% of aluminum grades. Thermal expansion is 21.5 µm/m·K (11.9 µin/in·°F).
Electrical3
ER4010-T4 conducts electricity at 36 % IACS, better than 55% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is good (62/100), better than 67% of aluminum grades.
Sustainability4
Producing a kilogram of ER4010-T4 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-T4's machinability is fair (50/100, worse than 65% of aluminum grades); weldability excellent (92/100); formability good (55/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with ER4010-T4
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.
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.
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 | — |
ER4010-T4 — frequently asked
What is ER4010-T4 used for?
ER4010-T4 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-T4?
ER4010-T4 has a typical yield strength of 125 MPa (18.1 ksi) and a tensile strength of 230 MPa (33.4 ksi) — weaker than 75% of aluminum grades. Strength varies by condition: see the 5 listed tempers.
Is ER4010-T4 easy to machine?
Reasonably — machinability is rated fair (50/100, worse than 65% 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-T4 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-T4?
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-T4 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-T4?
ER4010-T4 is rated for continuous use to about 120°C (248 °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.
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. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.