Approved GMA Welding Wires for Structural Repairs
Describes approved GMA welding wires for use in structural repairs.
Use only approved GMA (gas metal arc) welding wire for structural repairs on Tesla vehicles.
Warning
Failure to follow all welding safety precautions, including the use of
personal protective equipment, could result in serious injury or property damage. Only
technicians who have successfully met Tesla’s requirements for welding training are
authorized to weld structural components on Tesla vehicles.
Warning
To maintain vehicle crash integrity, use the welding wires specified in
this document to perform GMA welding on Tesla vehicles.
CAUTION
Before GMA welding, make sure that the structural adhesive is dry to the
touch.
CAUTION
Before GMA welding, perform a test weld using material of the same gauge
and type to make sure that the welding equipment settings produce a satisfactory
joint.
Approved GMA Welding Wire
Use only approved the GMA welding wires listed below for structural repairs on Tesla vehicles.
| Material | Approved Welding Wire | Part Number | Thickness |
|---|---|---|---|
| Aluminum | ER4145 | AlcoTec: 414505047 Lincoln Electric: ED037457 Tesla: 1022767-00-A |
1.2 mm diameter |
| Mild Steel | ER70S-6 (any) Bohler Union X96 |
Vendor-specific Pro-Spot: 50-7040 |
.8 mm diameter |
| High-Strength Steel | Bohler Union X96 | Pro-Spot: 50-7040 | .8 mm diameter |
| Ultra High-Strength Steel | Bohler Union X96 | Pro-Spot: 50-7040 | .8 mm diameter |
Note
Part numbers were current at the time of publication. Use the revision listed or later,
unless otherwise specified in the Parts Manual.
Note
All Tesla-approved welders use 5 lb spools of welding wire.
For information on the material used for specific body components on Tesla vehicles, refer to Body Structure Materials and Allowed Operations.