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Other Aluminum Welding Processes

Other Aluminum Welding Processes. Resistance Welding. Learning Activities View Slides; Read Notes, Listen to lecture Do on-line workbook. Lesson Objectives When you finish this lesson you will understand:. Keywords. Weld Bonding.

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Other Aluminum Welding Processes

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  1. Other Aluminum Welding Processes

  2. Resistance Welding • Learning Activities • View Slides; • Read Notes, • Listen to lecture • Do on-line workbook • Lesson Objectives • When you finish this lesson you will understand: Keywords

  3. Weld Bonding Adhesives are Epoxy, modified-epoxy, or elastomeric urethane adhesives, sometimes with fillers. When conductive metal fillers are used, welding parameters are nearly the same as those used for welding without adhesives Messler, R, “Joining of Advanced Materials” Butterworth-Heinemann, 1993

  4. Weld Bonding • Advantages • Increased static tensile and/or shear strength • Increased fatigue life • Gas tight or fluid tight bonds • Improved corrosion resistance • Complete interface bonding for load transfer • Disadvantages • High percent of irregular shaped nuggets • Higher percentage of expulsion • Alternate Process • Weld then back-infiltrate with low-viscosity adhesive Messler, R, “Joining of Advanced Materials” Butterworth-Heinemann, 1993

  5. Weld Bonding • Variables That Can Effect Weld Bond Quality • Aluminum Alloy Type • Type of Adhesive • Presence of a Forming Lubricant • Metal Surface Treatment • Effect on • Weld Current (Heat) Required to Produce Weld • Strength of Weld McCleary, S & Hulting, F, “Weldbonding of Aluminum Automotive Body Sheet”, SAE Paper 950715, 1995

  6. Lower Surface Resistance Lower Adhesive Resistance Higher Bulk Resistance Oil Film Higher Resistance McCleary, S & Hulting, F, “Weldbonding of Aluminum Automotive Body Sheet”, SAE Paper 950715, 1995

  7. Roll Spot & Seam Welding Aluminum • Higher Current than Steel - lower resistance, shunting • Excessive travel speed can result in Al pick-up on wheel - Increase time between welds, reduce travel speed • Radius face wheel - face radii 1-10 inch • Clean wheels: • After every 3-5 revolutions - continuous • After eve4y 10-20 revolution - Roll Spot welding • Or continuous cleaning

  8. AWS Welding Handbook, Vol 3, 1996

  9. Capacitor Discharge Stud Welding of Aluminum • Use AC to charge capacitors • Three Processes • Drawn Arc (inert gas shield) • Initial Contact • Initial Gap(preferred) • Two Ground Clams for even Current Distribution AWS Welding Handbook

  10. Capacitor Discharge Stud Welding of Aluminum • Studs commonly made of Al-Mg Alloys (high strength good ductility) • Base metal 1100, 3000 & 5000 series low copper 7000 series AWS Welding Handbook

  11. AWS Welding Handbook

  12. AWS Welding Handbook

  13. AWS Welding Handbook

  14. Flash Welding of Aluminum • Equipment similar to that used for steel • More rapid platen motion than for steel - softer material • Higher currents - less resistance • Electrodes fabricated from tool steel to prevent sticking

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