How XINXIN WELDING Helped a Collision Repair Workshop Reduce Panel Distortion and Better Preserve Corrosion

Protection

 

Introduction

Modern vehicles are engineered with increasingly thin, galvanized high-strength steel panels to reduce weight while

improving corrosion resistance. These materials perform exceptionally well on the road—but they also demand greater

precision during repair.

One independent collision repair workshop experienced recurring heat-related issues during conventional MIG welding.

Rather than replacing equipment, the workshop worked with XINXIN WELDING to evaluate whether a different filler metal

could provide a better solution.

 

Project Background

Industry: Automotive Collision Repair

Location: Central Europe

Vehicle Type: Mid-size passenger vehicles and SUVs

Repair Scope: Replacement and joining of galvanized outer body panels

Typical components included door outer panels, quarter panels, wheel arch sections, roof skins and rear body panels.

Most joints involved galvanized steel between 0.7 mm and 1.0 mm thick.

             

 

Existing Repair Process

The workshop used conventional MIG welding with carbon steel wire and an Ar/CO₂ shielding gas mixture. Despite

optimizing welding parameters, technicians continued to experience damage to the zinc coating, panel distortion, excessive

finishing work and rising repair costs.

 

Engineering Evaluation

XINXIN WELDING recommended evaluating CuSi-A Silicon Bronze Welding Wire (AWS A5.7 ERCuSi-A) using a MIG

brazing process with 100% argon shielding gas. The existing MIG equipment was retained and only minor parameter

adjustments were required.

 

Trial Results

• Better preservation of the galvanized coating due to lower heat input.

• Reduced distortion on thin sheet metal.

• Cleaner brazed joints with minimal spatter.

• Less grinding before painting.

• Improved workshop productivity through shorter repair cycles.

 

Why CuSi-A Performs Differently

Unlike conventional steel welding, MIG brazing with CuSi-A melts the silicon bronze filler while exposing the surrounding

galvanized steel to significantly lower thermal stress. For suitable applications specified or approved by vehicle manufacturers,

this helps preserve corrosion protection while producing clean, consistent joints.

 

Why Choose XINXIN WELDING

XINXIN WELDING manufactures CuSi-A Silicon Bronze Welding Wire using high-purity raw materials and strict quality

control. Every production batch is inspected for chemical composition, wire diameter, feeding stability, arc performance and

brazing quality. OEM and private-label services are available.

 

Conclusion

For repair shops working with galvanized sheet steel, CuSi-A MIG brazing offers a practical solution for reducing heat

distortion, preserving corrosion protection and improving repair efficiency where the process is appropriate and follows vehicle

manufacturer repair procedures.