Car bodies of metros, underground trains, trams, regional and high-speed trains are built from large aluminium extrusions and sheets. MIGAL.CO supplies the matching welding wires with Deutsche Bahn (DB) approval: MA-5183, MA-5087 and MA-5356 for high-strength, crack-resistant joints, MA-4043 for crack-sensitive 6xxx joints and MA-5754 for AlMg3 sheet. All five are also TÜV approved; MA-5183, MA-5087 and MA-5356 additionally carry DNV, Lloyd's Register, Bureau Veritas and ABS approvals.

Which wire for which joint?

Typical base materials in car body construction 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-6005A, 6082, 6106 extrusions side walls, roof and floor profiles MA-5183 or MA-5087 higher weld strength than AlSi fillers (Rm 275/285 MPa)
EN AW-6xxx with high dilution or rigid clamping root passes, crack-sensitive nodes MA-4043 (ER4043) AlSi weld metal prevents solidification cracking
EN AW-5083, 5086 sheet floor plates, end walls, underframe MA-5183 (ER5183) naturally hard, high tensile strength and elongation
EN AW-7020 (AlZnMg) highly loaded structural parts MA-5087 or MA-5183 AlMg fillers recommended for AlZnMg base metals
EN AW-5754, 5052 sheet cladding, interior parts MA-5754 (S Al 5754) Mg content matches the base material
anodised or visible parts interior and visible components MA-5356 (ER5356) nearly colour-matched after anodising

What matters in rail vehicle construction

  • Long, mechanised welds on 20–25 m car bodies: MA-5183, MA-5087 and MA-5356 come in 140 kg Jumbo and 240 kg Jumbo XL drums, MA-4043 in 80 kg Eco and 140 kg Jumbo drums – fewer wire changes, less downtime.
  • Wire feeding over long distances from drum to gantry or robot: roller-guided conduits and feed assist drives, see long-distance wire feeding for aluminium.
  • Porosity: vacuum-packed wire, dry storage, removal of the oxide layer – see welding of aluminium.
  • Documentation: rail vehicle manufacturers weld to EN 15085 and need approved filler metals – the DB and TÜV approvals of the MIGAL.CO wires are listed on every data sheet.

Approvals

Certificates: approvals aluminium.

Wire DNV LR BV ABS KR TÜV DB
MA-4043 ✓ ✓
MA-5087 ✓ ✓ ✓ ✓ ✓ ✓
MA-5183 ✓ ✓ ✓ ✓ ✓ ✓
MA-5356 ✓ ✓ ✓ ✓ ✓ ✓ ✓
MA-5754 ✓ ✓

Frequently asked questions

Which welding wire is used for aluminium car bodies?

For 6xxx extrusions and 5xxx sheet, AlMg fillers such as ER5183 or S Al 5087 are used where strength counts, and ER4043 where solidification cracking must be avoided. MIGAL.CO MA-5183, MA-5087, MA-5356, MA-4043 and MA-5754 are approved by Deutsche Bahn.

ER5183 or ER4043 for 6082 extrusions?

ER5183 gives a considerably stronger weld (about 275 MPa vs. 120 MPa tensile strength). ER4043 is less sensitive to solidification cracking with high dilution and rigid clamping. Note that AlSi weld metal turns dark grey after anodising.

Do you supply drums for mechanised welding?

Yes. MA-5183, MA-5087 and MA-5356 in 140 kg Jumbo and 240 kg Jumbo XL drums, MA-4043 in 80 kg Eco and 140 kg Jumbo drums.

Can I test the wire first?

Yes – request a free test spool.