Increasing trend of welding Aluminium parts in Automotive Industry
In the automobile sector, aluminium is becoming more and more popular as a way to improve vehicle fuel efficiency and better comply with industry rules. As a result, the demand for welding aluminium parts in the automotive industry is increasing.
The automotive sector most commonly uses welding, heat-bonding, and glueing procedures to attach aluminium pieces. Conventional welding of aluminium alloys poses no significant technological or managerial challenges. There are no issues when making high-quality aluminium joints with traditional, less-efficient slag-free welding techniques.
Welding using a coated electrode, on the other hand, does not provide adequate weld quality, as porous structures with a cracking tendency arise. As a result, welding with coated electrodes is used sparingly and on minor structural components. Refer (Fig.1).
The most popular non-slag welding processes used on the industrial scale are TIG and MIG methods.
Fig.1 – Welding Al parts
MIG welding, short for Metal Inert Gas welding, is a popular welding procedure that joins metal components using a continuously fed wire electrode and a shielding gas. It is appropriate for a wide range of applications in the automotive, construction, and industrial industries due to its high efficiency, adaptability, and ease of use. MIG welding delivers clean and exact welds, requiring less cleanup. Welders can produce varying penetration depths and weld bead profiles by adjusting the wire feed speed and voltage. Overall, MIG welding is popular due to its speed, quality, and versatility in a variety of metalworking operations.
Tips to help ensure success in welding aluminium parts
Welding fresh aluminium can be difficult even for seasoned welders. Repair welding on aluminium on a vehicle that has been exposed to dirt, mud, gravel, and other contaminants can be even more difficult.
Proper cleaning, training, and the use of aluminum-specific welding equipment and consumables are crucial for success in aluminium vehicle repair applications.
Frame welded with the MIG method
The advantages of MIG welding method are as follows:
- Universality – the ability to weld all metals in all positions
- High welding efficiency – higher from coated electrodes and TIG method
- Relatively low cost of welding consumables
- High quality of welds and
- Possibility to automate the method
Auto body businesses should also invest in modern welding equipment made exclusively for aluminium.
A system designed for aluminium
Many manufacturers offer systems or welding packages designed to function together when selecting welding equipment and consumables for aluminium welding. The power supply, cable, gun, and other consumables, such as the nozzle, contact tip, and liner, are included in these bundles.
These packages are intended to be a turnkey welding solution, which is especially useful for those with less expertise welding aluminium. These systems simplify setup, have simple interfaces, and provide consistent arc performance, making it easier to carry out excellent repairs.
Another method auto body companies can prepare for the transition to aluminium welding is to learn aluminium cleaning processes. It is critical to clean the material as thoroughly as possible and to remove the coating of aluminium oxide on the material’s surface. This could make fixing vehicles that have been on the road difficult since dirt and gravel can become embedded in the base material. Greater care and attention to detail will be required during the cleaning procedure.
When cleaning, technicians or welding operators must first remove grease or other contaminants with a solvent such as acetone. Then, prior to welding, use a stainless-steel brush to remove the aluminium oxide.
Investing in the future of automotive engineering through aluminum welding – witness the journey of lighter, more efficient, and high-performance vehicles. Get in touch with us to know more in detail about the welding aluminium parts in automotive industry. You can also reach us via our toll free number 1800 203 3544 or visit us at https://www.ats-elgi.com/ for more details about our automotive garage equipment’s.
Lakshman, S. & Rajeshwar, S. & Naveen, K.S. & Davinder S., & Pargat S. An Evaluation of TIG Welding Parametric Influence on Tensile Strength of 5083 Aluminium Alloy. International Scholarly and Scientific Research and Innovation. 2013. Vol. 7. P. 99-107.
Yao, L. & Wenjing, W. & Jijia, X. & Shouguang, S & Liang, W. & Yuan, M. & Yujii, W. Microstructure and mechanical properties of aluminium 5083 weldments by gas tungsten arc and gas metal arc welding. Materials Science Engineering. 2012. Vol. 549. P. 7-13.
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