5 Ways Aluminum Welding Is Essential In Manufacturing Aftermarket Automotive Parts

5 Ways Aluminum Welding Is Essential In Manufacturing Aftermarket Automotive Parts

Automotive manufacturing is one of the largest industry users of aluminum welding procedures around the world. The light weight of aluminum welding makes it a must for more fuel-efficient vehicles.

However, aluminum welding isn’t just necessary for manufacturing brand new vehicles. Aluminum welding is also essential for making many of the most popular aftermarket automotive parts as well. Since the buyers of aftermarket parts are usually purchasing them for higher performance and greater vehicle durability, aluminum welding is used in conjunction with forging and molding to create parts that live up to the buyer’s expectations.

Not all aftermarket parts for vehicles require welding, but these five types of automotive parts rely on skilled aluminum welding services.


1. Suspension and Frame Replacements

Original frame and suspension parts almost always feature at least one instance of aluminum welding per piece, but aftermarket parts tend to feature even more aluminum welding. While forging and casting the aluminum is necessary to give the parts the strength they need to handle the intense forces targeting the frame of a vehicle, there are many limitations to how much of a part can be formed in one piece.

Since aftermarket parts must conform to the fit requirements of the original vehicle, they’re often made with more aluminum welding joints. This allows aftermarket parts distributors to create fewer molds and adjust the parts to fit a wider range of different models and makes.

Ordering custom molds and tooling equipment for every model and make you want to offer for sale can quickly bankrupt even a popular aftermarket parts manufacturer. Aluminum welding is the best way to reconfigure universal parts to make them properly fit a wider range of vehicles, increasing your product line with minimal extra cost.


2. Fuel Tanks

Fuel tanks are one of the most popular aftermarket parts made with aluminum welding because stock versions contribute a lot of weight to a vehicle. When you’re trying to trim down every pound for better performance, you need a lightweight aluminum fuel tank you can trust.

Aluminum welding is the fastest way to manufacture a wide range of tanks to fit the needs of as many vehicles as possible. If you’re not using aluminum welding for the edges, you’ll have to order different tooling equipment for nearly every tank design you offer. Even in manufacturing settings where molds and tooling equipment is already in use, aluminum welding is still necessary for securely attaching the inlets and outlets that link the tank to the rest of the fuel system.


3. Light Weight Radiators

Today’s new cars tend to feature aluminum radiators as stock options for the weight reduction. To save on materials, manufacturers also tend to work plastic into the design. But plastic has no place in such as essential part as a radiator where pressure and heat can cause the material to degrade quickly.

Fully aluminum radiators are best manufactured with at least a little aluminum welding. In the heaviest duty radiator designs, cooling tanks are attached directly to the core with the help of aluminum welding. Some aftermarket manufacturers also use aluminum welding for attaching the headers, especially in all-in-one radiator designs. Consider expanding your aluminum welding use to make more durable radiators that demand a higher price from the consumer.


4. Aftermarket Bumpers

Few aftermarket parts require as much aluminum welding as bumpers and similar shock absorbing parts. Aluminum welding is the most secure way to attach the mounting brackets to the bumper bar itself. Adhesives and rivets can’t compare to a solid aluminum welding bead. Since tough bumpers are one of the most important safety features found on a car, aluminum welding is the best manufacturing method to prevent injury or damage claims in the future.

Aside from standard bumpers, aluminum welding is also necessary for the most efficient and affordable manufacturing of specialty bumper parts like cow-catchers and brush guards.


5. Body Panels

Finally, body panels deserve spot aluminum welding in necessary points rather than just reliance on automotive adhesives. Switching from steel to aluminum welding materials for body panels cuts down on total vehicle weight more than any other aftermarket change. If you’re interested in selling aftermarket body panels that your customers can still rely on in a collision, you need aluminum welding to at least join crucial edges.

Aluminum welding can also be used to add bead lines for physical reinforcement to prevent unwanted flexing during a drive.


It’s not always possible for an aftermarket parts manufacturer to invest in their own aluminum welding equipment. Save money and get better results by outsourcing the task to one of the many aluminum welding subcontractors we have listed here at the European Subcontracting Network. Peruse our listings and find your new service provider today.