Electric vehicles use aluminium wherever weight and heat dissipation matter: battery trays and frames from 6xxx extrusions, cast housings for motors, inverters and gearboxes, and conductors made of pure aluminium. MIGAL.CO supplies MA-4043 and MA-5183 for extrusion structures, MA-4046, MA-4047 and MA-4018 for castings and MA-1070 and MA-1450 for pure aluminium. With an estimated 3.9 kg CO₂e per kg of wire, the filler metal also helps to lower the carbon footprint of the battery system.
Which wire for which joint?
Typical base materials in electric vehicles and the matching MIGAL.CO wire. For other combinations see the material selection table for aluminium alloys.
| Base material | Typical use | Recommended wire | Why |
|---|---|---|---|
| EN AW-6060, 6063, 6082 extrusions | battery trays, frames, crash structures | MA-4043 or MA-5183 | 4043 against solidification cracking, 5183 for higher weld strength (Rm 275 MPa) |
| AlSi10Mg castings (EN AC-43000, 43100) | motor, inverter and gearbox housings | MA-4046 (S Al 4046) | Si content matches the cast alloy |
| AlSi12 castings (EN AC-44100, 44200) | housings, cast nodes | MA-4047 (ER4047) | 12 % Si matches the cast alloy |
| AlSi7Mg castings | housings to be heat-treated | MA-4018 (S Al 4018) | heat-treatable: Rm 310 MPa in T6 |
| pure aluminium EN AW-1050A, 1070A | conductors, cell connectors | MA-1070 or MA-1450 | matching pure aluminium filler; alloying elements would lower the electrical conductivity |
What matters in battery and drive production
- Leak tightness: battery trays with cooling channels must be tight – vacuum-packed wire, dry storage and removal of the oxide layer keep porosity low; see welding of aluminium.
- Distortion: long welds on thin-walled extrusions – careful tacking and sequence planning keep the tray flat.
- Robot lines: MA-4043, MA-4046 and MA-4047 in 80 kg Eco and 140 kg Jumbo drums, MA-5183 in 140 kg Jumbo and 240 kg Jumbo XL drums; soft AlSi wires need low-friction feeding – see long-distance wire feeding for aluminium.
- Carbon footprint: about 3.9 kg CO₂e per kg of wire (cradle-to-gate, estimate) – details on low-carbon aluminium welding wire. For car bodies and conventional vehicles see automotive.
Frequently asked questions
Which welding wire is used for aluminium battery trays?
Battery trays from 6xxx extrusions are welded with ER4043 where solidification cracking is the risk and with ER5183 where higher weld strength is needed. Low porosity is essential for trays with cooling channels.
Which wire for cast motor and inverter housings?
The silicon content of the filler should match the cast alloy: S Al 4046 (AlSi10Mg) for AlSi10Mg castings, ER4047 (AlSi12) for AlSi12 castings, S Al 4018 (AlSi7Mg) for AlSi7Mg castings that are heat-treated afterwards.
Which wire for pure aluminium conductors?
A pure aluminium filler matching the base metal, such as MA-1070 (Al99.7) or MA-1450 (Al99.5Ti). Alloyed fillers would lower the electrical conductivity of the joint.
Can I test the wire first?
Yes – request a free test spool.