What is Wheel Welding? A Guide to Alloy Wheel Welding and Safer Alternatives
By WheelRestore
Alloy wheels are known for their sleek design and performance, but damage from potholes or curbs can be costly. When cracks go beyond cosmetic scratches, welding is often considered. But is welding aluminium wheels really safe? And are there better options?
Wheel welding is a method to repair damaged alloy wheels by adding new metal. While effective, it raises concerns about safety, durability, and performance. Not all cracks or welds are safe, especially for high-value aluminium wheels that require strict structural standards
This guide covers the wheel welding process, the advantages and disadvantages of traditional welding, and introduces cold-spray aluminium repair as a safer, low-heat alternative.
Wheel welding is the process of repairing cracked or damaged wheels by adding new metal to the affected area. This involves filling the damaged section with filler material, typically aluminium, to restore the wheel’s structural integrity. The process entails joining two or more pieces of metal using heat and pressure, effectively addressing issues like cracks or deeper gouges.
This method is often used on cracked alloy wheels, on wheels that have curb damage that cuts deep into the rim, or small structural breaks near the lip.
Aluminium alloy wheel welding is an often overlooked method, but is actually one of the most advanced alloy wheel repair methods. With an alloy wheel welding you can re-establish the wheel’s strength and shape, thereby avoiding replacing wheels.
How to Weld Alloy Wheels: The Traditional Process
There are many different welding techniques that can be used to repair damaged wheels. The most common method used is where an electric arc is used to melt and fuse the metal together. This method gives great strength and durability.
Another type of welding is TIG (Tungsten Inert Gas), where you use a tungsten electrode to create a precise and controlled weld. This type of weld is often used for delicate repairs. It is very precise, but significantly slower than other types of methods.
The last type of welding is the MIG (Metal Inert Gas) technique, where you use a wire electrode to create a strong and efficient weld. This method is commonly used for larger repairs. This method is faster than TIG, but less neat than others.
The process of welding involves:
Damage assessment of the wheel to find out if it is safe to repair with welding.
Cleaning and opening up the crack and damaged area so it can accept new material.
Welding the crack using one of the three methods as described above.
Machining, polishing, or even diamond cutting to restore the finish.
Balancing the wheel, pressure testing, and inspecting for residual cracks.
Is Welding Alloy Wheels Safe?
The short answer to that question would be: sometimes, but not always.
There are several factors that need to be taken into consideration before welding a wheel, because there are many risks involved. Welding aluminium wheels requires intense heat. This can warp the wheel, weaken the alloy, and create residual stress. Elevated temperatures alter the grain structure of the alloy wheels, weakening them.
It is also important to assess the wheel before repair, because repeated welding can weaken the wheel with time. Location of the damage also matters. Cracks on the inner barrel or cosmetic rim edges are generally safer to aluweld than cracks on spokes or hub areas, which are structural and load-bearing.
It can be safe to weld wheels, but it depends on the quality of the weld, the type of damage, and how the wheel is inspected afterward.
Aluminium wheel welding has been a common practice for decades, but it comes with several drawbacks. One significant issue is heat distortion; the welding process raises the rim’s temperature to hundreds of degrees, which can lead to warping. Additionally, the heat-affected zone around the weld may become softer and more susceptible to cracks, resulting in weakened metal.
Safety is another concern, as poor welds can fail under load, making professional inspection essential. Furthermore, the quality of the weld is not always consistent; it heavily relies on the technician’s skill, setup, and inspection process.
This is particularly true for diamond-cut alloy wheels, where a precise finish is crucial. In such cases, welding often creates more problems than it resolves.
The Modern Alternative: Cold-Spray Aluminium Repair
Traditional welding isn’t the only option anymore. At Wheel Restore, we’ve developed the Aluminium Spraying Machine (ASM), which is a purpose-built solution for repairing alloy wheels without welding.
Instead of welding the wheel with high heat, the Aluminium Spraying Machine uses a cold-spray aluminium that applies filler at low temperatures (below 50°C). The material is built directly into the damaged area.
A cold spray aluminium repair makes sure to avoid cracking, heat distortion, or metallurgical changes. Achieves up to 85–90% alloy match for seamless strength and finish.
Why it’s safer and smarter than welding
No heat damage ensures that the wheel structure is preserved, while being OEM-safe guarantees full compliance with manufacturer standards.
The user-friendly design features intuitive controls, eliminating the need for welding expertise. Its integrated workflow allows it to fit seamlessly inside our blasting machine, enabling both preparation and spraying in a single workstation.
Additionally, it is durable enough to withstand tire changes, impacts, and seasonal wear.
We recommend that you choose to repair using the traditional welding method if the wheel has a deep, structural crack in a load-bearing area.
If the wheel, on the other hand, has cosmetic rim damage, gouges, or repeated repairs where welding would risk further weakening. The ASM is also the better choice if the damage is on Diamond Cut wheels.
For most cosmetic and non-structural repairs, ASM offers a faster, safer, and more sustainable approach.
Seamless Integration Into Your Current Wheel Repair Setup
The ASM is designed to fit right into your current wheel repair setup.
The compact spray gun can fit directly into the cabinet of the Wheel Blasting Machine. This allows wheel repairers to both blast and full from a single workstation. You save time, and you make sure that the cold spray is handled in a controlled ATEX-certified environment.
After using the ASM, the wheel can be transferred directly to the Diamond Cutting Machine. If you fill the crack with just a bit more aluminium than it needs, the Diamond Cutter will just cut away the residual material ensuring a great refinish.
Looking to Start a Wheel Repair Business?
Wheel welding has long been a go-to repair method for cracked alloy wheels—but it comes with risks. With new technology like the Aluminium Spraying Machine (ASM), workshops can now repair wheels without the dangers of heat, distortion, or inconsistent welds.
If you’re looking for a safe, OEM-compliant, and repeatable solution to wheel repair, it’s time to leave traditional welding behind and step into the future with ASM.
Are you looking to start a wheel repair business? Let us help you with everything you need in machines and equipment to get started. Contact us today for a demo of the ASM system and start offering safe, faster repairs
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What is Wheel Welding? A Guide to Alloy Wheel Welding and Safer Alternatives
Alloy wheels are known for their sleek design and performance, but damage from potholes or curbs can be costly. When cracks go beyond cosmetic scratches, welding is often considered. But is welding aluminium wheels really safe? And are there better options?
Wheel welding is a method to repair damaged alloy wheels by adding new metal. While effective, it raises concerns about safety, durability, and performance. Not all cracks or welds are safe, especially for high-value aluminium wheels that require strict structural standards
This guide covers the wheel welding process, the advantages and disadvantages of traditional welding, and introduces cold-spray aluminium repair as a safer, low-heat alternative.
Table of Contents
What is Wheel Welding?
Wheel welding is the process of repairing cracked or damaged wheels by adding new metal to the affected area. This involves filling the damaged section with filler material, typically aluminium, to restore the wheel’s structural integrity. The process entails joining two or more pieces of metal using heat and pressure, effectively addressing issues like cracks or deeper gouges.
This method is often used on cracked alloy wheels, on wheels that have curb damage that cuts deep into the rim, or small structural breaks near the lip.
Aluminium alloy wheel welding is an often overlooked method, but is actually one of the most advanced alloy wheel repair methods. With an alloy wheel welding you can re-establish the wheel’s strength and shape, thereby avoiding replacing wheels.
How to Weld Alloy Wheels: The Traditional Process
There are many different welding techniques that can be used to repair damaged wheels. The most common method used is where an electric arc is used to melt and fuse the metal together. This method gives great strength and durability.
Another type of welding is TIG (Tungsten Inert Gas), where you use a tungsten electrode to create a precise and controlled weld. This type of weld is often used for delicate repairs. It is very precise, but significantly slower than other types of methods.
The last type of welding is the MIG (Metal Inert Gas) technique, where you use a wire electrode to create a strong and efficient weld. This method is commonly used for larger repairs. This method is faster than TIG, but less neat than others.
The process of welding involves:
Is Welding Alloy Wheels Safe?
The short answer to that question would be: sometimes, but not always.
There are several factors that need to be taken into consideration before welding a wheel, because there are many risks involved. Welding aluminium wheels requires intense heat. This can warp the wheel, weaken the alloy, and create residual stress. Elevated temperatures alter the grain structure of the alloy wheels, weakening them.
It is also important to assess the wheel before repair, because repeated welding can weaken the wheel with time. Location of the damage also matters. Cracks on the inner barrel or cosmetic rim edges are generally safer to aluweld than cracks on spokes or hub areas, which are structural and load-bearing.
It can be safe to weld wheels, but it depends on the quality of the weld, the type of damage, and how the wheel is inspected afterward.
Also read: How to Repair Alloy Wheel Damage: A Step-by-Step Guide for OEM-quality Results
The Limitations of Traditional Wheel Welding
Aluminium wheel welding has been a common practice for decades, but it comes with several drawbacks. One significant issue is heat distortion; the welding process raises the rim’s temperature to hundreds of degrees, which can lead to warping. Additionally, the heat-affected zone around the weld may become softer and more susceptible to cracks, resulting in weakened metal.
Safety is another concern, as poor welds can fail under load, making professional inspection essential. Furthermore, the quality of the weld is not always consistent; it heavily relies on the technician’s skill, setup, and inspection process.
This is particularly true for diamond-cut alloy wheels, where a precise finish is crucial. In such cases, welding often creates more problems than it resolves.
The Modern Alternative: Cold-Spray Aluminium Repair
Traditional welding isn’t the only option anymore. At Wheel Restore, we’ve developed the Aluminium Spraying Machine (ASM), which is a purpose-built solution for repairing alloy wheels without welding.
Instead of welding the wheel with high heat, the Aluminium Spraying Machine uses a cold-spray aluminium that applies filler at low temperatures (below 50°C). The material is built directly into the damaged area.
A cold spray aluminium repair makes sure to avoid cracking, heat distortion, or metallurgical changes. Achieves up to 85–90% alloy match for seamless strength and finish.
Why it’s safer and smarter than welding
No heat damage ensures that the wheel structure is preserved, while being OEM-safe guarantees full compliance with manufacturer standards.
The user-friendly design features intuitive controls, eliminating the need for welding expertise. Its integrated workflow allows it to fit seamlessly inside our blasting machine, enabling both preparation and spraying in a single workstation.
Additionally, it is durable enough to withstand tire changes, impacts, and seasonal wear.
In other words: no torches, no cables, no hassle.
Also read: What is a Blasting Cabinet? A Cleaner, Greener Alternative to Traditional Sandblasting
Cold-Spray Aluminium Repair vs. Welding
So, which is the best way to weld alloy wheels?
We recommend that you choose to repair using the traditional welding method if the wheel has a deep, structural crack in a load-bearing area.
If the wheel, on the other hand, has cosmetic rim damage, gouges, or repeated repairs where welding would risk further weakening. The ASM is also the better choice if the damage is on Diamond Cut wheels.
For most cosmetic and non-structural repairs, ASM offers a faster, safer, and more sustainable approach.
Also read: What is a Diamond Cut Machine – And Why is it Essential for Today’s Workshops?
Seamless Integration Into Your Current Wheel Repair Setup
The ASM is designed to fit right into your current wheel repair setup.
The compact spray gun can fit directly into the cabinet of the Wheel Blasting Machine. This allows wheel repairers to both blast and full from a single workstation. You save time, and you make sure that the cold spray is handled in a controlled ATEX-certified environment.
After using the ASM, the wheel can be transferred directly to the Diamond Cutting Machine. If you fill the crack with just a bit more aluminium than it needs, the Diamond Cutter will just cut away the residual material ensuring a great refinish.
Looking to Start a Wheel Repair Business?
Wheel welding has long been a go-to repair method for cracked alloy wheels—but it comes with risks. With new technology like the Aluminium Spraying Machine (ASM), workshops can now repair wheels without the dangers of heat, distortion, or inconsistent welds.
If you’re looking for a safe, OEM-compliant, and repeatable solution to wheel repair, it’s time to leave traditional welding behind and step into the future with ASM.
Are you looking to start a wheel repair business? Let us help you with everything you need in machines and equipment to get started. Contact us today for a demo of the ASM system and start offering safe, faster repairs