Aluminium reduces vehicle weight – in the body, in extrusion structures and in cast parts, and increasingly in electric vehicles. MIGAL.CO supplies the matching wires: MA-4020 (AlSi3Mn) for joint welding of outer skin parts in car body construction, MA-4043 and MA-4047 for crack-sensitive 6xxx joints and AlSi castings, and MA-5183 and MA-5087 where weld strength counts. With an estimated 3.9 kg CO₂e per kg of wire, MIGAL.CO wire helps to lower the carbon footprint of the vehicle.
Which wire for which joint?
Typical base materials in automotive and the matching MIGAL.CO wire. For other combinations see the material selection table for aluminium alloys.
| Base material | Typical use | Recommended wire | Why |
|---|---|---|---|
| outer skin sheet | car body outer skin parts | MA-4020 (S Al 4020) | developed for joint welding in car body construction |
| EN AW-6060, 6063, 6082 extrusions | frames, crash and battery structures | MA-4043 or MA-5183 | 4043 against solidification cracking, 5183 for higher weld strength |
| AlSi12 cast alloys (EN AC-44100, 44200) | cast nodes, housings | MA-4047 (ER4047) | 12 % Si matches the cast alloy |
| AlSi10Mg cast alloys (EN AC-43000, 43100) | housings, repair welding | MA-4046 (S Al 4046) | Si content matches the cast alloy |
| EN AW-5xxx sheet, EN AW-7020 | chassis parts, highly loaded joints | MA-5183 or MA-5087 | naturally hard AlMg weld metal, Rm 275/285 MPa |
What matters in automotive production
- Robot lines need consistent wire: MA-4020, MA-4043, MA-4046 and MA-4047 come in 80 kg Eco and 140 kg Jumbo drums, MA-5183 and MA-5087 in 140 kg Jumbo and 240 kg Jumbo XL drums.
- Soft AlSi wires are hard to feed: roller-guided conduits and feed assist drives keep the feed force low – see long-distance wire feeding for aluminium.
- Anodised or coated parts: AlSi weld metal turns dark grey after anodising – where colour match matters, use an AlMg filler such as MA-5356.
- Carbon footprint: about 3.9 kg CO₂e per kg of wire (cradle-to-gate, estimate) – details on low-carbon aluminium welding wire.
Frequently asked questions
Which welding wire is used for aluminium car body parts?
For joint welding of outer skin parts, AlSi3Mn (S Al 4020) was developed specifically for car body construction. For 6xxx extrusion structures, ER4043 or ER5183 are used depending on whether crack resistance or strength is the priority.
Which wire for welding AlSi castings?
The silicon content of the filler should match the cast alloy as closely as possible: ER4047 (AlSi12) for AlSi12 castings, S Al 4046 (AlSi10Mg) for AlSi10Mg castings.
How large is the carbon footprint of MIGAL.CO aluminium wire?
About 3.9 kg CO₂e per kg of wire (cradle-to-gate, estimate based on supplier data and own figures 2025) – roughly a quarter of the global average for primary aluminium.
Can I test the wire first?
Yes – request a free test spool.