Aluminum ER4011-AW (As-welded deposit)
Heat-treated state · default condition
ASTM AWS A5.10 ER4011
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.
Values for the AW condition
Other ER4011 tempers and conditions
ER4011 is listed in 5 conditions; see the grade overview at ER4011.
Compare all 5 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
AWDefaultThis page 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 |
What is ER4011-AW?
ER4011-AW is ER4011 heat treated to AW — 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. ER4011-AW 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). ER4011-AW 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).
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-AW properties
Typical room-temperature values for ER4011-AW; 10 are specific to this condition. Other listed values are ER4011 reference data and may not represent this condition. Bars are the position among aluminum grades.
Physical3
ER4011-AW 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-AW 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-AW 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-AW 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-AW 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-AW'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. Confirm any required mill or lot documentation when quoting.
Working with ER4011-AW
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.
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.
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 | — |
ER4011-AW — frequently asked
What is ER4011-AW used for?
ER4011-AW 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-AW?
ER4011-AW 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-AW 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-AW 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-AW?
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-AW 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-AW?
ER4011-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 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.
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. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.