Lightweight Aluminum Alloy Wire for Transportation

Specification

Applications and Solutions

• Rail Car Bodies: Welding the large aluminum extrusions that form the shell, roof, and floor of high-speed passenger trains and subways.

• Automotive Structural Components: Fabrication of aluminum body-in-white (BIW), chassis, and battery enclosures for electric vehicles.

• Truck and Trailer Bodies: Welding structural components, flatbeds, tankers, and refrigerated transport units.

• Marine Vessels: Welding superstructures and high-speed hull sections where weight savings are paramount for speed and stability.

FAQ

• Q: Which aluminum base metals are most common in rail transportation?A: High-strength 6000 series extrusions (e.g., 6061, 6082) are dominant. ER5356 is the most commonly specified filler metal for these assemblies.

• Q: Why is consistent wire feeding so critical in transportation welding?A: Transportation component welding is heavily automated. Inconsistent wire feeding (poor cast or helix) causes arc wander, spatter, and stops, leading to expensive downtime and rework in high-volume, cost-sensitive production lines.

• Q: Is post-weld heat treatment (PWHT) used in transportation fabrication?A: Rarely for full assemblies (too large), but PWHT is used for smaller, critical cast components or sub-assemblies welded with heat-treatable fillers like ER4943 to regain T6 strength.