Article
As the Russia-Ukraine war continues, global oil prices continue to rise, and lightweight new energy vehicles are becoming more and more popular. The quality of the vehicle determines fuel consumption. Lightweighting the vehicle body can significantly reduce the weight of the vehicle, and the fuel usage can be significantly reduced.
To make the car body lightweight, it must be made of aluminum alloy. The density of aluminum alloy is only 1/3 of steel. It is rich in mineral resources and affordable. Resistance spot welding, Projection welding is the main way to connect aluminum alloy structures, but aluminum has the following problems during the spot welding process 1. The melting point of aluminum alloy is 660, and it is difficult to shape and deform. 2. The resistivity is low and the heat loss is fast, that is, the heat generated is difficult to dissipate quickly. 3. High thermal conductivity and large softening area 4. Poor stability, difficult to ensure welding temperature and heat preservation to form weld nugget 5. The current flows quickly and cracks are easily formed during the solidification process. 6. The surface has high resistance and can easily form a loop with high-melting-point oxides to hinder current flow. 7. It is more difficult for aluminum alloys to form a nugget with sufficient plasticity. 8. The small electrode cannot cover the aluminum alloy weld nugget and all softened areas.
So when spot welding 1. Large-diameter flat or spherical electrodes should be selected. 2. It is advisable to use high current for short time, about 32-45KA5 cycles for 0.1 seconds to weld. 3. The cooling water flow should be twice the flow rate of other materials 4. The welding current is 3-5 times that of the steel plate 5. Use medium frequency spot welding, pressure 500-700KG
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