Aluminum ER4011
ASTM AWS A5.10 ER4011
ER4011 is an Al-Si-Mg filler in AWS A5.10 with added magnesium that raises as-welded strength on 6000 series and Al-Si-Mg casting joints without post-weld solution treatment.
Reference datasheet — ER4011 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
ER4011 tempers and conditions
ER4011 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: field or production welds on 6000-series extrusions and A356/A357 castings where PWHT is impossible; Mg gives higher as-welded strength than ER4043. | 100 | 185 | 6 | 55 HB | 39 % IACS |
AW + natural aging | Use when the joint sits at room temperature for weeks before loading — Mg₂Si natural aging adds a modest strength recovery over the freshly welded state. | 115 | 205 | 6 | 60 HB | 39 % IACS |
artificial aging only (typ. 155–175 °C) | Pick when the assembly can be oven-aged but not solution treated (distortion-sensitive weldments); gives most of the strength gain without quench distortion. | 165 | 235 | 5 | 70 HB | 41 % IACS |
solution treated and overaged (stabilized) | Use for dimensional stability and elevated-temperature service where a little strength is traded for reduced residual stress and better toughness. | 180 | 240 | 7 | 72 HB | 43 % IACS |
post-weld solution heat treat, quench and artificial age | Best choice for repaired A356/A357 castings and structural weldments that are fully re-heat-treated after welding — weld metal strength approaches that of the T6 casting base metal. | 225 | 290 | 5 | 80 HB | 39 % IACS |
Supply forms, finishes and certifications
Ways ER4011 is supplied — form, process route, surface or paperwork — without a datasheet of their own. The property values above apply.
| Option | What it is | Type |
|---|---|---|
F-WIRE | F | Supply form |
What is ER4011?
ER4011 is an Al-Si-Mg filler in AWS A5.10 with added magnesium that raises as-welded strength on 6000 series and Al-Si-Mg casting joints without post-weld solution treatment. It ships as drawn wire and straight rod, with F-WIRE, AW, AW-NA and AW-T5/T6/T7 conditions on file, and typical as-welded values of 100 MPa yield, 185 MPa tensile and 6 % elongation. Hot-crack sensitivity is slightly higher than ER4043, dilution into high-Mg 5000-series base metal should be avoided, and maximum service temperature is about 150 °C. ER4011 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). ER4011 has a yield strength of 100 MPa (14.5 ksi) and a tensile strength of 185 MPa (26.8 ksi) — weaker than 84% of aluminum grades. Elongation at break is 6% and the elastic modulus is 72 GPa (10.4 Msi).
What is ER4011 used for?
- 6000-series structural welding
- Cast alloy repair without PWHT
- A356/A357 casting welds
- Cast-to-extrusion node joints
- Automotive suspension casting repair
- Cast housing and cover repair
Advantages
- Readily welded — 90/100, better than 90% of aluminum grades
Limitations
- Hard to polish — 40/100, worse than 91% of aluminum grades
- Low strength — 100 MPa (14.5 ksi), worse than 84% of aluminum grades
ER4011 properties
Typical room-temperature values for ER4011-AW; bars are the position among aluminum grades.
Physical3
ER4011 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).
Mechanical11
ER4011 has a yield strength of 100 MPa (14.5 ksi) and a tensile strength of 185 MPa (26.8 ksi) — weaker than 84% of aluminum grades. Elongation at break is 6% and the elastic modulus is 72 GPa (10.4 Msi).
Thermal6
ER4011 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
ER4011 conducts electricity at 39 % IACS, better than 65% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is good (65/100), better than 71% of aluminum grades.
Sustainability4
Producing a kilogram of ER4011 takes about 200 MJ of energy and emits 13 kg of CO₂ — less than 60% of aluminum grades. Typical recycled content is 25%.
Manufacturability8
ER4011's machinability is fair (50/100, worse than 65% of aluminum grades); weldability excellent (90/100); 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. ER4011 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with ER4011
Is ER4011 easy to machine?
Machine weld beads with sharp PCD or polished carbide, high speed and flood coolant — the 7 % Si eutectic is abrasive and gummy in the as-welded state; machinability improves after T6.
Can ER4011 be welded?
Excellent GTAW/GMAW filler for A356/A357 castings and 6000-series extrusions; keep heat input moderate and avoid dilution into high-Mg 5000-series base metal, and be aware of slightly higher hot-crack sensitivity than ER4043.
Can ER4011 be formed, bent or molded?
Not a forming stock — supplied as drawn wire/rod; weld metal itself has limited ductility, so avoid post-weld bending of the bead.
ER4011 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 |
| Mgprovides age-hardening response | 0.45 – 0.7 | 0.55 |
| Tigrain refinement of weld metal | 0.04 – 0.2 | 0.12 |
| Fe | ≤ 0.2 | |
| Cu | ≤ 0.2 | |
| Mn | ≤ 0.1 | |
| Zn | ≤ 0.1 | |
| Berestricted for fume-toxicity reasons | ≤ 3×10⁻⁴ | |
| Others (each) | ≤ 0.05 | |
| Others (total) | ≤ 0.15 | |
| Al | balance |
What surface finishes work on ER4011?
Anodizes dark grey and blotchy because of the Si; use paint, chromate/Ti-Zr conversion coat or leave as-welded, and expect a visible color mismatch if the base metal is anodized.
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 ER4011 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- ASTM
- AWS A5.10 ER4011
- Other
- 4011
How much does ER4011 cost?
ER4011 is a premium-cost aluminum ($$$), cheaper than about 51% 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.
ER4011 — frequently asked
What is ER4011 used for?
ER4011 is typically used for 6000-series structural welding, cast alloy repair without PWHT, A356/A357 casting welds, cast-to-extrusion node joints, automotive suspension casting repair and cast housing and cover repair. In short: higher Mg than ER4043; strength without PWHT; 6000 series and casting filler.
What is the yield strength of ER4011?
ER4011 has a typical yield strength of 100 MPa (14.5 ksi) and a tensile strength of 185 MPa (26.8 ksi) — weaker than 84% of aluminum grades. Strength varies by condition: see the 5 listed tempers.
Is ER4011 easy to machine?
Reasonably — machinability is rated fair (50/100, worse than 65% of aluminum grades). Machine weld beads with sharp PCD or polished carbide, high speed and flood coolant — the 7 % Si eutectic is abrasive and gummy in the as-welded state; machinability improves after T6.
Can ER4011 be welded?
Yes — weldability is rated excellent (90/100). Excellent GTAW/GMAW filler for A356/A357 castings and 6000-series extrusions; keep heat input moderate and avoid dilution into high-Mg 5000-series base metal, and be aware of slightly higher hot-crack sensitivity than ER4043.
What surface finishes work on ER4011?
Anodizes dark grey and blotchy because of the Si; use paint, chromate/Ti-Zr conversion coat or leave as-welded, and expect a visible color mismatch if the base metal is anodized.
Can ER4011 be formed, bent or molded?
Not a forming stock — supplied as drawn wire/rod; weld metal itself has limited ductility, so avoid post-weld bending of the bead.
What is the maximum service temperature of ER4011?
ER4011 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 ER4011-AW and ER4011 AW-T6?
AW is the default condition — default condition: field or production welds on 6000-series extrusions and A356/A357 castings where PWHT is impossible; Mg gives higher as-welded strength than ER4043. AW-T6: best choice for repaired A356/A357 castings and structural weldments that are fully re-heat-treated after welding — weld metal strength approaches that of the T6 casting base metal. Yield strength is 100 MPa in AW versus 225 MPa in AW-T6.
How much does ER4011 cost?
ER4011 is a premium-cost aluminum ($$$), cheaper than about 51% 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 — AWS (2021)
- Registration Record of International Alloy Designations (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 filler selection) — ASM International (1993)
- Aluminum filler metal selection guides (ESAB / Lincoln / Hobart aluminum wire data) — various producers (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.