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  1. #21
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    Nov 2003
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    Thumbs up

    Thanks Galen..!!

    you are a valued technical resource....
    .

    *******************************************
    The more you know, The better you know, How little you know......

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

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  2. #22
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    Nov 2003
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    Question 4943 for ALUSIL casting...

    A question came up the other day about welding up an ALUSIL engine block bracket on an old Porsche 928S4....

    is 4943 the correct filler..?? if not what is??

    Did a little looking around and could not find a good answer...

    this is a structural member but NOT cylinder liner...

    ALUSIL is common in many european engines...

    anybody have an answer..?? Galen??

    Here is a thread on ALUSIL

    http://www.millerwelds.com/resources...m-engine-block

    and some good info on ALUSIL from it..

    Quote Originally Posted by captkipp View Post
    Alusil as a hypereutectic aluminium-silicon alloy (AlSi17Cu4Mg) contains approximately 70% aluminium and 30% silicon.[1][2] This alloy was created in 1927 by Schweizer & Fehrenbach[3] of Baden-Baden Germany and further developed by Kolbenschmidt.[2]

    The Alusil aluminium alloy is commonly used to make linerless aluminium alloy engine blocks.[4] Alusil, when etched, will expose a very hard silicon precipitate. The silicon surface is porous enough to hold oil, and is an excellent bearing surface. BMW switched from Nikasil-coated cylinder walls to Alusil in 1996 to eliminate the corrosion problems caused through the use of petrol/gasoline containing sulfur.

    Engines using Alusil include:

    Audi 2.4 V6[1][5]
    Audi 3.2 FSI V6[5]
    Audi 4.2 FSI V8[1][3]
    Audi 5.2 FSI V10
    Audi/Volkswagen 6.0 W12
    BMW N52 I6
    BMW M62 V8
    BMW N62 V8
    BMW V12[6]
    Porsche 928 V8
    Porsche 924S I4
    Porsche 944 I4
    Porsche 968 I4
    Porsche Cayenne V8[3]
    Last edited by H80N; 12-15-2013 at 11:25 AM.
    .

    *******************************************
    The more you know, The better you know, How little you know......

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus Mills, Lathes & a Rat Tail File..

  3. #23
    Join Date
    Oct 2012
    Location
    yuba city, CA
    Posts
    47

    Default actual alusil composition

    Quote Originally Posted by H80N View Post
    A question came up the other day about welding up an ALUSIL engine block bracket on an old Porsche 928S4....

    is 4943 the correct filler..?? if not what is??


    Here is a thread on ALUSIL

    http://www.millerwelds.com/resources...m-engine-block

    and some good info on ALUSIL from it..
    Below credit to Wiki:
    Alusil as a hypereutectic aluminium-silicon alloy (Al17Si4CuMg or A390) contains approximately 78% aluminium and 17% silicon.[1][2] This alloy was created in 1927 by Schweizer & Fehrenbach[3] of Baden-Baden Germany and further developed by Kolbenschmidt.[2]


    17% silicon content is a whale of a lot different than 30% silicon.
    The 30% content in Capt. Kidd's post is in error.

    http://www.steelnumber.com/en/steel_...p?name_id=1254

    The above link has equivalencies from US to European, etc. grades
    and compositions.

  4. #24
    Join Date
    Nov 2003
    Posts
    2,986

    Default

    Quote Originally Posted by dave powelson View Post
    Below credit to Wiki:
    Alusil as a hypereutectic aluminium-silicon alloy (Al17Si4CuMg or A390) contains approximately 78% aluminium and 17% silicon.[1][2] This alloy was created in 1927 by Schweizer & Fehrenbach[3] of Baden-Baden Germany and further developed by Kolbenschmidt.[2]


    17% silicon content is a whale of a lot different than 30% silicon.
    The 30% content in Capt. Kidd's post is in error.

    http://www.steelnumber.com/en/steel_...p?name_id=1254

    The above link has equivalencies from US to European, etc. grades
    and compositions.
    Dave

    Thanks for the corrected info...

    that makes the U.S. Equiv out to be.... B390.0
    .

    *******************************************
    The more you know, The better you know, How little you know......

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus Mills, Lathes & a Rat Tail File..

  5. #25
    Join Date
    Nov 2003
    Posts
    2,986

    Default

    I did find a German specialty rod for ALUSIL... that might be suitable..

    but I sure hate to order something from overseas if something domestic will do a good job..

    here is the datasheet..

    http://www.technolit.de/App/WebObjec.../Alusil-S.html


    Also found a source that claimed 4145 filler was suitable..

    http://www.weldingwire.com/applicati...pload/4145.pdf
    Last edited by H80N; 12-15-2013 at 01:43 PM.
    .

    *******************************************
    The more you know, The better you know, How little you know......

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus Mills, Lathes & a Rat Tail File..

  6. #26

    Default

    If the Alusil alloy is truly A390 then its chemistry is:

    16.0-18.0% silicon
    0.50% Fe
    4.0-5.0% Cu
    0.10% Mn
    0.45-0.65% Mg
    0.10% Zn
    0.20% Ti
    Remainder aluminum

    The German filler rod on the Techolit web page is nothing more than R4047 which is available at almost any welding distributor and has the closest match for silicon at 12%.

    4145 has probably the closest overall chemistry match:

    9.3-10.7% Si
    0.8% Fe
    3.3-4.7% Cu
    0.15% Mn
    0.15% Mg
    0.20% Zn

    On most filler metal selection charts 4043 and 4145 are normally listed for welding these types of castings (4047 and 4943 are interchangeable for 4043 in all applications).

    In a nutshell, 4047, 4145, 4943 or 4043 should work.

  7. #27
    Join Date
    Aug 2010
    Location
    Los Angeles
    Posts
    1,163

    Default

    Quote Originally Posted by Hobart Aluminum View Post

    In a nutshell, 4047, 4145, 4943 or 4043 should work.
    Awesome.

    Thanks!
    Nothing welded, Nothing gained

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  8. #28
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    Nov 2003
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    2,986

    Thumbs up

    Just noticed and read this AWS article on 4943.. from Galen's answer

    http://www.nxtbook.com/nxtbooks/aws/...tid=Cover1#/36

    figured if I missed it... others may have also

    Really good background and alloy comparison...

    pretty cool..
    .

    *******************************************
    The more you know, The better you know, How little you know......

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus Mills, Lathes & a Rat Tail File..

  9. #29

    Default

    I use 4943. It flows real nice.....welded up a 6061-tc angle frame the other day.....I still use 4043 for all cast repairs though...Dave
    Quote Originally Posted by H80N View Post
    Just noticed and read this AWS article on 4943.. from Galen's answer

    http://www.nxtbook.com/nxtbooks/aws/...tid=Cover1#/36

    figured if I missed it... others may have also

    Really good background and alloy comparison...

    pretty cool..

  10. #30
    Join Date
    Nov 2003
    Posts
    2,986

    Default

    Quote Originally Posted by JerseyWelder View Post
    I use 4943. It flows real nice.....welded up a 6061-tc angle frame the other day.....I still use 4043 for all cast repairs though...Dave
    From all that I can see... 4943 offers superior performance to 4043 in welding cast as well..

    what is the reasoning in using 4043 for that purpose if you have 4943 on hand..??

    The merits of 4943 on TIG welding cast aluminum as opposed to other alloys like 4043 was the reason for starting this thread in the first place...and all points pro and con.. so if you could elaborate why... am sure many of us would like to hear..
    Last edited by H80N; 02-02-2014 at 08:46 AM.
    .

    *******************************************
    The more you know, The better you know, How little you know......

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus Mills, Lathes & a Rat Tail File..

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