Aluminum ER4010-T6
Temper
ASTM AWS A5.10 ER4010
T6 = solution heat treated and artificially aged
Standard choice for structural casting repairs: weld metal responds like A356-T6 and nearly matches base-metal strength.
Values for the T6 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 |
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 |
T6This page 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-T6?
ER4010-T6 is ER4010 in the T6 temper — standard choice for structural casting repairs: weld metal responds like A356-T6 and nearly matches base-metal strength. ER4010-T6 has a yield strength of 215 MPa (31.2 ksi) and a tensile strength of 285 MPa (41.3 ksi) — stronger than 58% of aluminum grades. Elongation at break is 5% and the elastic modulus is 72 GPa (10.4 Msi). ER4010-T6 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; T6 is available on request or by drawing note.
Advantages
- Readily welded — 92/100, better than 95% of aluminum grades
Limitations
- Hard to polish — 45/100, worse than 76% of aluminum grades
ER4010-T6 properties
Typical room-temperature values for ER4010-T6; 10 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-T6 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-T6 has a yield strength of 215 MPa (31.2 ksi) and a tensile strength of 285 MPa (41.3 ksi) — stronger than 58% of aluminum grades. Elongation at break is 5% and the elastic modulus is 72 GPa (10.4 Msi).
Thermal6
ER4010-T6 is rated for continuous service to 150°C (302 °F). It conducts heat at 151 W/m·K (87.2 BTU/hr·ft·°F), better than 63% of aluminum grades. Thermal expansion is 21.5 µm/m·K (11.9 µin/in·°F).
Electrical3
ER4010-T6 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-T6 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-T6's machinability is good (65/100, better than 62% of aluminum grades); weldability excellent (92/100); formability fair (45/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with ER4010-T6
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-T6 — frequently asked
What is ER4010-T6 used for?
ER4010-T6 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-T6?
ER4010-T6 has a typical yield strength of 215 MPa (31.2 ksi) and a tensile strength of 285 MPa (41.3 ksi) — stronger than 58% of aluminum grades. Strength varies by condition: see the 5 listed tempers.
Is ER4010-T6 easy to machine?
Reasonably — machinability is rated good (65/100, better than 62% 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-T6 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-T6?
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-T6 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-T6?
ER4010-T6 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.
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.