Kumacandelo angundoqo emveliso yala maxesha, anje ngezithuthi zombane, i-aerospace, kunye{0}}nesiphelo esiphezulu sombane, itekhnoloji ye-aluminiyam ye-welding idlala indima ebalulekileyo. I-aluminium alloys zizinto ezikhethiweyo zokunciphisa ubunzima besakhiwo kunye nokuphucula ukusebenza kakuhle ngenxa yeempawu zabo ezintle kakhulu.
Nangona kunjalo, iimpawu ezizodwa ze-aluminiyam-i-thermal conductivity ephezulu kakhulu kunye nokwakheka kwe-oxide ekhawulezayo{1}}yenza indawo yayo yokuwelda ibenzima kakhulu kunentsimbi yesintu. Oku kufuna ulungiselelo olungqongqo phambi kwe-welding. Kuphela kungokucokisekileyo kwangaphambili{4}}ulungiselelo lweweld apho umatshini wokuwelda unokusebenza kakuhle, ekugqibeleni unike{5}}amandla aphezulu,{6}}ethembeke kakhulu.
Esi sikhokelo sichaza ngokucwangcisiweyo onke amanyathelo aphambili okulungiselela ukuwelda indawo ye-aluminium, ukusuka kwimigaqo yekhemikhali yonyango lomphezulu ukuya kukhetho lwezixhobo kunye noseto lweparamitha yenkqubo engundoqo. Ibonelela ngedatha yereferensi esemthethweni kunye nezisombululo zesiphene esisebenzayo, esijolise ekuncedeni abavelisi kunye neengcali baphucule kakhulu izinga lempumelelo kunye nozinzo lomgangatho we-aluminium indawo yokuwelda.
Imingeni eyodwa kunye neMigaqo yeAluminiyam yeSpot Welding
Ubume be-aluminium indawo yokuwelda buvela kwiimpawu ezimbini eziphambili:
- I-High Thermal Conductivity:I-Aluminiyam ye-thermal conductivity imalunga namaxesha amane entsimbi. Oku kuthetha ukuba ngexesha le-welding, ubushushu buphuma kwindawo ye-weld nugget ngokukhawuleza, okwenza kube nzima ukuba i-nugget yenze okanye ifikelele ubungakanani obufunekayo. Ke ngoko, ukuwelda kwamabala e-aluminiyam kufuna ngokugqithisileyo kwangoku kwangoku kunye namaxesha amafutshane kakhulu ukuwelda ukuze kugxininiswe amandla.
- Umaleko olukhuni weAluminiyam ye-Oxide (Al₂O₃):Imiphezulu ye-aluminiyam ngokukhawuleza yenza ifilimu eqinile ye-aluminiyam oxide xa ibonakaliswe emoyeni. Lo maleko we oxide unendawo yokunyibilika malunga ne 2050℃, ngelixa ialuminiyam ecocekileyo inyibilika kwi 660℃kuphela . Lo -uphezulu wokunyibilika-kwe-oksidi yombane yi-conductor yombane engekho mgangathweni, nto leyo eyandisa kakhulu ukuxhathisa ukudibana, okukhokelela ekungazinzini kwangoku, isitshizi esiqatha, kunye nomqobo obalulekileyo wokwakheka kwe-nugget.
Ke ngoko, undoqo we-aluminiyam ephumeleleyo yokuwelda ilele ekususeni ngokufanelekileyo umaleko we-oxide kunye nokulawula ngokuchanekileyo amandla okuwelda.
Unyango olungaphezulu: Ukususwa kwee-oksidi kunye nezinto ezingcolisayo-iSiseko seMpumelelo
Unyango olufanelekileyo lomphezulu lelona nyathelo libaluleke kakhulu kwi-aluminiyam spot welding. Injongo yalo kukususa ngokupheleleyo umaleko we-aluminium oxide kunye nayiphi na igrisi okanye ukungcola okunokuchaphazela umgangatho we-weld.
1. Indlela yoNyango lweMichiza (Ilungele iMveliso yeVolumu ePhezulu{1})
Unyango lwemichiza yeyona ndlela icokisekileyo nefanayo yokususa ioksidi, ifaneleke ngakumbi-imigca yemveliso ezenzekelayo enkulu.
- Ukucocwa kweAlkaline:Qala ngokusebenzisa isisombululo esibuthakathaka se-alkaline (njenge-5-10% isisombululo se-sodium hydroxide) yokucoca ukucwiliswa, ngokuqhelekileyo ukulawulwa imizuzwana engama-30-60. Eli nyathelo lijolise ekususeni igrisi kunye neeoksidi ezininzi.
- I-Acid engathathi hlangothi kunye nokuhlanjululwa:Oku kufuneka kulandelwe yi-neutralization kunye nesisombululo se-acidic kunye nokuhlanjululwa ngokucokisekileyo ngamanzi amaninzi asebenzayo ukuqinisekisa ukuba akukho ntsalela yeekhemikhali ehlala phezu komhlaba.
- I-advanteji:Umphezulu ophathwayo unoburhabaxa obufanayo kunye nokucoceka okuphezulu, okulungeleka kakhulu ukufezekisa ukuchasana koqhagamshelwano oluzinzileyo.
2. Indlela yoNyango lweMechanical (Ilungele iibhetshi ezincinci okanye ukulungiswa kwendawo)
Unyango ngoomatshini lususa umaleko weoksidi ngokwasemzimbeni, kodwa kufuneka lwenziwe ngononophelo ukuthintela ukungeniswa okungcolisayo okanye uburhabaxa obungalinganiyo bomphezulu.
- Ukukhethwa kwesixhobo:Kufuneka kusetyenziswe ibrashi yocingo yentsimbi engenastainless okanye i-aluminiyam ekhethekileyo yokususa i-abrasive tool. Ukusetyenziswa kweebrashi zocingo eziqhelekileyo kunqatshelwe ngokungqongqo ukuphepha ukungcoliswa kwe-iron ion ye-aluminium surface.
- IiMfuno zokuSebenza:Unyango kufuneka lwenziwe ngokukhawuleza phambi kwe-welding. Umphezulu we-aluminiyam ophathwayo kufuneka ulondoloze uburhabaxa obungaguqukiyo, kwaye ukuwelda kufuneka kugqitywe kwiiyure ezisi-8 emva konyango, njengoko umaleko we-oxide uya kuphinda -ujiye kwaye uthobe umgangatho we-weld.
ULungiselelo lweSixhobo: Ukuphucula umatshini wakho wokuwelda iSpot{0}}Isiqinisekiso saMandla
Indawo ye-aluminiyam yokuwelda ibeka iimfuno eziphezulu kakhulu kwisixhobo kunentsimbi, ngokuyintloko ngokwemiqathango yozinzo lwemveliso yangoku kunye nolawulo oluchanekileyo.
1. IiMfuno zoMbane: MFDCUmatshini we-Spot Welding
Ngenxa ye-aluminium ephezulu yombane, ukuxhathisa kwayo okuphantsi kufuna i-welding yangoku amaxesha angama-2-3 aphezulu kunoko kwentsimbi ukufezekisa igalelo lobushushu elifanayo.
- oomatshini indawo welding MFDC zibonelela imveliso ezinzileyo DC yangoku, leyo, xa kuthelekiswa noomatshini bemveli AC, ivumela ulawulo oluchanekileyo phezu isizukulwana ubushushu. Oku kunciphisa ngokufanelekileyo ukuguquguquka kwangoku okunokuthi kuchaphazele ukubunjwa kwe-nugget, kuyenze ibe lolona khetho lukhethwayo lokuwelda indawo ye-aluminium kwimizi-mveliso yeemoto kunye ne-aerospace.
2. UkuKhethwa kwe-Electrode kunye neMigangatho yoLondolozo
Ii-Electrodes zinyamezela umthwalo omkhulu we-thermal kunye nomngcipheko wokunamathela kwindawo ye-aluminium yokuwelda. Ukhetho nokugcinwa kwazo zibalulekile.
| Into eqhelekileyo | Imfuneko eCetyisiweyo | Injongo kunye noMgaqo | |
| 1 | Izinto ze-Electrode | {0}}I-copperivity ye-Copper Alloy ePhezulu (umzekelo, Ukusasazwa{3}}Ikopolo eyomeleziweyo, i-Conductivity Enkulu kuno okanye ilingana ne-80% ye-IACS) | Iqinisekisa utshintshiselwano olusebenzayo ngoku, yehlisa ukuzifudumeza kwe-electrode, kwaye yehlisa umngcipheko wokuxuba nge-aluminiyam (i-electrode sticking). |
| 2 | Electrode Diameter | Ukutyeba Ngaphantsi okanye ilingana no-1.0 mm amaphepha: Ø13 - Ø16 mm; Ukutyeba Mkhulu kuno okanye ilingana no 2.0 mm amaphepha: Ø20 - Ø25 mm | Uqinisekisa ukuba indawo yoqhagamshelwano ye-electrode ihambelana nobukhulu beshiti ukufezekisa ubuninzi obufanelekileyo bangoku. |
| 3 | Ubume be-Electrode | Ukusetyenziswa okucetyiswayo kweRadius okanye iFlethi enengcebiso zeChamfer | Unqanda i-electrode echongiweyo, enciphisa ukungena, ukutshiza, kunye nokunxiba kwe-electrode. |
| 4 | Inkqubo yokupholisa | Kufuneka ixhotyiswe ngesixokelelwano sokupholisa samanzi esidibeneyo{0}, esinesantya sokuhamba esingekho ngaphantsi kwe-4-6 L/min. | Ukususa ngokukhawuleza ubushushu kwi-electrode, ukuthintela ubushushu obugqithisileyo be-electrode obukhokelela ekuncamatheleni kunye nomgangatho ombi weld. |
| 5 | Ukunxiba Frequency | Ukunxiba ukukhanya okucetyiswayo rhoqo nge-welds engama-20-50 | Ukususwa ngexesha elifanelekileyo le-aluminium alloy buildup kwindawo ye-electrode ukugcina ukuchasana okuzinzileyo kunye nokuma kwe-electrode. |
Itheyibhile yeParameter egunyazisiweyo: Umthetho weGolide weeWelds eziPheleleyo
Ukuseta iiparamitha ze-welding yindibaniselwano yamava kunye nesayensi. Le theyibhile ilandelayo ibonelela ngemilinganiselo yereferensi ye-aluminiyam ye-alloy spot welding ngokusekelwe kwimigangatho yoshishino (efana ne-AWS C1.1M). Uvavanyo lwewelding kufuneka lwenziwe ukuze kuqinisekiswe kwaye kulungiswe kakuhle{3}} ezi setingi.
| Ukutyeba kwephepha (mm) | Amandla e-Electrode (kN) | I-Welding yangoku (kA) | Ixesha lokuwelda (Izijikijelo/60Hz) | Nugget Diameter (mm) |
| 0.8 + 0.8 | 2.0 - 3.0 | 18 - 22 | 3 - 6 | 4.0 - 5.0 |
| 1.2 + 1.2 | 3.0 - 4.5 | 22 - 28 | 5 - 8 | 5.0 - 6.5 |
| 2.0 + 2.0 | 5.0 - 7.0 | 30 - 40 | 8-12 | 7.0 - 8.5 |
I-Welding yangoku kunye nexesha lixabiso lokubhekisela. Iiparamitha ezizizo kufuneka zihlengahlengiswe ngokusekelwe kuhlobo oluthile lwe-alloy, imodeli yomatshini we-welding, kunye nemeko ye-electrode.
Amanqaku angundoqo oPhuculo lweParameter
- I-Weld yangoku:Le yeyona parameter ibaluleke kakhulu, imisela ngokuthe ngqo igalelo lobushushu. I-aluminiyam ifuna umsinga ophezulu, isoloko isebenzisa imowudi ye-pulse yangoku -, apho i-pulse yangaphambili{2}}yobushushu ithi igqobhoze kumaleko weoksidi, ilandelwa yi-welding pulse engundoqo ukwenza i-nugget.
- Amandla e-Electrode:Amandla e-electrode kufuneka anele ukuqinisekisa uqhagamshelwano oluqinileyo phakathi kwamaphepha amabini, ukunciphisa ukuxhatshazwa kokuqala, kunye nokucinezela i-spatter. Nangona kunjalo, uxinzelelo olugqithisileyo lunokukhawulezisa ukutshatyalaliswa kobushushu kwaye kufuneka luhambelane nemimiselo yangoku kunye nexesha.
- Ixesha le-Weld:Ixesha lifutshane kakhulu, lilinganiswa ngokwemijikelo. Ixesha elide kakhulu likhokelela ekuqokeleleni kobushushu obugqithisileyo, kubangele isitshizi kunye nokutshisa{1}}ngabo; ixesha elifutshane kakhulu lithintela ukwakheka kwe-nugget.
ULawulo lokusiNgqongileyo kunye naManyathelo axhasayo
Ngaphaya kondoqo "Umntu, umatshini, izinto, iNdlela", ukulawula okusingqongileyo kunye nokuxhasa amanyathelo yinxalenye eyimfuneko yokuqinisekisa umgangatho we-weld.
Inkqubo yokufudumeza kwangaphambili
Kumashiti ashinyeneyo e-aluminiyam okanye amandla aphezulu-i-alloys, ukufudumeza kwasekhaya kuyacetyiswa phambi kokuba kufakwe i-welding, ngamaqondo obushushu alawulwa phakathi kwe-80-120 degree. Ukufudumeza kwangaphambili kunokusebenza ngokufanelekileyo:
- Nciphisa Uxinzelelo lwe-Thermal:Yehlisa isantya sokupholisa kwindawo yeweld, uthintele ukuqhekeka kwiindawo eziphezulu{0}}zamandla ngexesha lokupholisa.
- Zinzisa ukuxhathisa:I-Homogenize ubushushu bezinto eziphathekayo, ezinceda ekuzinziseni i-welding yangoku.
Inkqubo yokuxhasa
Xa udibanisa amashiti amancinci okanye izakhiwo ezikhethekileyo, usebenzisa i-steel stainless okanye i-graphite backing plate njengenkqubo yenkxaso inokuthintela ngokufanelekileyo ukuba izinto ezincinci zinganyibiliki ngenxa yokushisa okuphezulu kunye nokuqinisekisa ukubunjwa okuzinzileyo kwe-weld nugget.
Ukuqinisekiswa komgangatho kunye nezisombululo zesiphene esiqhelekileyo
Nokuba kulungiselelwe ngokucokisekileyo, iziphene ezahlukahlukeneyo zisenokwenzeka kwimveliso. Ukuseka inkqubo ebanzi yokuqinisekisa umgangatho kunye nendlela yokusombulula iziphene kubalulekile.
Iindlela zokuqinisekisa uMgangatho
- Alulo-uVavanyo oluLonakalisayo (NDT):Iindlela eziqhelekileyo ziquka uvavanyo lwe-ultrasonic kunye nokuhlolwa kwe-X-yeray, esetyenziselwa ukujonga ubungakanani be-nugget, iziphene zangaphakathi (ezifana ne-porosity kunye nokuqhekeka), kunye nokungena.
- Uvavanyo Lokonakalisa (DT):Ibandakanya uvavanyo lobunzima-lokucheba kunye nohlalutyo olukhulu{1}} lwecandelo. Uvavanyo lwe-tensile luqinisekisa amandla omatshini we-weld; macro-uhlalutyo lwecandelo yeyona ndlela yokulinganisa ngokuchanekileyo i-nugget yedayamitha kunye nokumila, eqinisekisa useto lweparameter.
Iziphene eziqhelekileyo kunye nezisombululo zobuNgcali
| Uhlobo lwesiphene | Unobangela wokuqala | Uthintelo kunye nesisombululo | |
| 1 | I-Spatter | Ifilimu ye-oxide ayisuswanga ngokupheleleyo; irempu yangoku{0}phezulu kakhulu; amandla angonelanga | Qinisa ukucoca phambi{0}}kwangaphambili; sebenzisa{1}}ubushushu bangaphambili ukugqobhoza umaleko weoksidi; ngokufanelekileyo ukwandisa amandla e-electrode. |
| 2 | Electrode Sticking | Ukupholisa okungonelanga; izinto ezingafanelekanga ze-electrode; ixesha welding lide kakhulu | Jonga amanzi{0}}amanzi enkqubo yokupholisa kunye nobushushu; sebenzisa i-Dispersion{1}}Ii-electrode zeCopper ezomeleziweyo; ukunciphisa ixesha le-welding okanye ukwandisa ukunxiba rhoqo. |
| 3 | Nugget Offset | Ulungelelwaniso olubi lwe-electrode; Umahluko omkhulu kubukhulu bephepha | Lungisa ulungelelwaniso lwe-electrode; sebenzisa i-electrode eqhubayo kancinci kwicala elicekethekileyo lephepha ukulinganisa ubushushu. |
| 4 | Ukushwabana/Ukuqhekeka | Ukupholisa ngokukhawuleza kakhulu; ixesha elingonelanga lokubamba; uvakalelo oluphezulu lwe-alloy | Yandisa Ixesha Lokubamba; sebenzisa ithambeka langoku-ezantsi; shushumbisa amaphepha. |
| 5 | Ukutshiswa komphezulu oMphezulu/ ukuNgena ngaphakathi ngokugqithisileyo | Umphezulu we-electrode ongcolileyo; umsinga ogqithisileyo; imilo ye-electrode engafanelekanga | Gqoka rhoqo i-electrode; ngokufanelekileyo ukunciphisa yangoku okanye ukwandisa indawo yoqhagamshelwano electrode. |
FAQ Aluminiyam Spot Welding
Umbuzo: Ngaba uyayibona i-aluminiyam ye-weld ene-welder yendawo eqhelekileyo?
A: Kusenokwenzeka ukuba kubhityile kakhulu, {0}iisampulu ezingabalulekanga, kodwa iintsimbi ezininzi{1}}ezilungelelanisiweyo zokuwelda azikwazi ukubonelela ngoku, ulawulo lwenkani kunye nokupholisa okufunekayo kwi-welding ezinzileyo ye-aluminiyam kwishishini.
Umbuzo: Ngaba i-aluminiyam idinga indawo ye-welding yangoku kunentsimbi?
A: Ngokubanzi ewe. Ukunganyangeki kombane okuphantsi kwe-aluminiyam kunye nokutshatyalaliswa kobushushu okukhawulezayo kudla ngokufuna umsinga ophakamileyo uhanjiswe ngexesha elifutshane.
Umbuzo: Ngaba i-MFDC ingcono kune-AC ye-aluminium ye-welding?
A: I-MFDC inikezela ngolawulo oluchanekileyo lwangoku kunye nokuhambelana kakuhle kwe-automation, kodwa umthamo wangoku womatshini, amandla, i-impedance yesibini kunye nokupholisa kuhlala kubalulekile ngokulinganayo.
Umbuzo: Ngaba amashiti e-aluminiyam kufuneka acocwe phambi kokuba adibane?
A: Ewe. I-oyile, ukungcola kunye nemeko ye-oxide engahambelaniyo inokuphazamisa ukuchasana noqhagamshelwano. Indlela yokucoca kufuneka ilawulwe kwi-alloy ethile kunye nenkqubo yokuvelisa.
Umbuzo: Kutheni i-aluminiyam inamathela kwii-electrode zokuwelda?
A: Izizathu eziqhelekileyo ziquka ukugqithiswa kwe-electrode, i-aluminium pickup, ixesha eligqithisiweyo le-weld, ukuxinana okuphezulu kwangoku kunye nokugcinwa kwe-electrode eyaneleyo.
Q: Wazi njani ukuba indawo ye-aluminium yomelele ngokwaneleyo?
A: Sebenzisa uvavanyo oluchaziweyo lomatshini okanye lwe-metallographic. Inkangeleko yomphezulu iyodwa ayinakuqinisekisa ubungakanani benugget okanye umgangatho we weld yangaphakathi.
Umbuzo: Ngaba i-aluminiyam inokudityaniswa ngentsimbi okanye ubhedu?
A: Ukudibanisa isinyithi esingafaniyo kunzima ngakumbi ngenxa yokungalingani kokumelana, ukuhamba kobushushu kunye nokwakheka kwe-intermetallic brittle. Umdibaniso kufuneka uvavanywe njengenkqubo eyahlukileyo kunokusebenzisa ialuminiyam eqhelekileyo{1}ukuya{2}}kwishedyuli yealuminiyam.
Ukuqukumbela
I-aluminium ethembekileyo ye-welding yendawo ixhomekeke kwinkqubo epheleleyo, kungekhona kwisetingi enye yangoku. Umphezulu wezinto eziphathekayo, imveliso yomatshini, amandla e-electrode, inkqubo yokupholisa, ukulungelelaniswa kwezixhobo kunye nendlela yokuqinisekisa umgangatho kufuneka isebenze kunye.
Qala ngokuchaza isitakhi samaphepha esichanekileyo kunye neemfuno zokusebenza. Emva koko misela ifestile yokusebenza ngovavanyo lwesampulu kunokukopa itafile yeparamitha ngqo kwimveliso. Xa umatshini unomthamo owaneleyo wangoku kwaye inkqubo ilawulwa ngokufanelekileyo, i-resistance spot welding inokubonelela ngokukhawuleza, i-aluminiyam ephindaphindayo edibeneyo ye-automotive, i-automotive, i-appliance kunye nezicelo zokuvelisa ezizenzekelayo.
