铝车身点焊技术(002).pptx

铝合金点焊技术 Aluminum resistance spot weld technology;;材料参数 Material Parameters;焊接时间 Weld Cycles 焊接时间 Weld Cycles;热导率与熔核温度 Thermal conductivity/nugget temperature 铝合金有高导热系数以及很大的软化区域 High thermal conductivity of Al produces large softened zone 球面或小直接焊接面电极帽不能覆盖铝合金焊核以及全部软化区域 Ball nose/small face dia. electrodes cannot contain Al nugget and softened region 需要大直径平面，其他与钢材焊接相同的电极帽 Requires large, fairly flat, well aligned, and normal-to-sheet electrodes 采用低密度电流减少生产影响 Lower current density drives higher currents and sensitivity to production variation 焊枪电极帽使铝合金焊核/PMZ/软化区域稳定 Stiff weld guns will stabilize electrode over Al nugget/PMZ/softened metal zone 低焊核温度—电极无软化变形 Low nugget temperature – no electrode mushrooming ;热量产生位置比较 Heat generation comparison 通用镀锌钢板 Typical Galvanized steel sheet 通用铝合金板材 Typical Aluminum sheet 理想铝合金板材以及合适/有效的冷却 Ideal aluminum sheet welding obtained with proper /effective cooling ;森德莱推荐使用与铝合金接触面为超大半径球面来代替平面的电极帽。 CenterLine recommends large radius faced electrodes to localize heat at aluminum sheet interface instead of the surface;Browne, D., Model to Predict, IBEC’95, Adv Tech Processes, 1995;确保所有载流部件满足电流与热导率要求Assure all current carrying components meet ECTC ( electrical current and thermal conductivity) requirements. 需要较大的截面 Larger cross sections required. 必须考虑焦耳定律的要求 Joules Law must be considered. 热量=I x I x R x T (2-3次焊接后，二次侧热指数会上升) Heat=I x I x R x T (2-3 times sec. current means exponential heat rise in secondary) 软连接，电极臂，电极杆等 Shunt, arms, shanks, etc. 不需要使用水冷电缆 Avoid water-cooled cables ;更大的冷却水流量需求 Increase Water Flow Rate;基于铝合金属性所建立的设计准则 Recommended Joint Designs Based Upon These Properties;点焊过程中的压力分布 Pressure Distribution During Spot Welding;Auhl, JR, SAE 940160, 1994;热导率 Thermal Conductivity 比钢材更大 Greater than that of steel 铝合金的热损失率更高 The rate of heat loss from the weld is much greater in aluminum 需要短时间，大电流 Require short welding times and high curre