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Both the plateau and concentric bumps are used in penetrating light metal surfaces for suitable current passage. In another embodiment, the domed surface is shaped with concentric terraces for engagement with the workpieces.
The welding electrodes of this invention are typically made of copper-base alloys with suitable electrical conductivity and strength to resist weld force application when pressed against outer opposing surfaces of assembled sheets or other workpieces shaped to be welded together. The method further involves pressing the preheated welding electrode and another welding electrode against opposite sides of the workpiece stack-up, with the preheated welding electrode abutting the aluminum or aluminum alloy workpiece, and passing an electrical current between the two welding electrodes at a weld site to initiate and grow a molten weld pool within the aluminum or aluminum alloy workpiece.
Preheating the welding electrode that eventually abuts the aluminum workpiece furnishes more heat to the aluminum workpiece than would otherwise be the case during resistance spot welding of the workpiece stack-up. The overall strength and integrity of the weld joint established between the workpieces can hence be improved by use of the disclosed method.
The rings of ridges are positioned on the weld face to contact and impress into a sheet metal workpiece surface during resistance spot welding. If the welding electrode is used during resistance spot welding of light metal alloy workpieces, such as those of aluminum alloy or magnesium alloy, the rings of ridges on the weld face can contribute to improved welding performance.
The concentric circular ridge or groove design for the electrode cap not only provides improved welding performance of the electrode, it is also a textured pattern that can be restored very rapidly to the electrode face as it is re-dressed for continued welding operations.
A liquid-cooled high voltage primary conductor electrically connects the weld control to the transformer primary input and a low voltage secondary conductor electrically connects the transformer secondary output to the welding gun to energize the opposed electrodes.
In one step a welding electrode is provided. The welding electrode has a weld face. In another step, the weld face of the welding electrode is shaped to have a desired radius of curvature. The shaped weld face is then textured to a desired surface roughness, and resistance spot welding using the welding electrode is performed to the aluminum alloy workpieces. In yet another step, the weld face is dressed to an extent sufficient to remove contamination build-up that may have accumulated on the weld face from the aluminum alloy workpieces.
A method of maintaining a welding electrode during its use in resistance spot welding aluminum alloy workpieces may include several steps. In one step, a weld face of the welding electrode is textured to have a desired surface roughness. In another step, the weld face is textured again to have a desired surface roughness after a first number of individual resistance spot welds are performed. And in yet another step, the weld face is dressed to remove a desired depth of material of the welding electrode after a second number of individual resistance spot welds are performed.
The second number of individual resistance spot welds is greater than the first number of individual resistance spot welds. In another step, the dressed weld face is textured to a desired surface roughness. The system further includes a processing device configured to output a weld quality signal representing a quality of an aluminum weld based at least in part on the attribute measured.
A method includes measuring an attribute of at least one of an aluminum nugget forming a joint of a workpiece and a welding process, determining a quality of an aluminum weld based at least in part on the attribute measured, and outputting a weld quality signal representing the determined quality.
The size, shape, and elevation or depths of the protrusions or intrusions are determined for the formation of suitable spot welds in and between metal workpieces such as aluminum or steel panels for vehicle bodies. The protrusions or intrusions are also conceived and used to form an image on at least a visible surface of the welded article to produce an attractive appearance on the surface of the welded sheet. In each welding application, the electrode face is sized and shaped to form a good weld at the interfacial surfaces of contacting sheet surfaces, i.
The invention relates to a vehicle body structure in the region of the A-pillar and the windshield cross member, including an A-pillar on both sides of the body, wherein in the pillar construction of the A-pillar, the A-pillar has an A-pillar inner steel plate oriented approximately vertically and in the vehicle longitudinal direction. An approximately horizontal windshield cross member is connected at the ends thereof to the associated A-pillar inner steel plate by means of a welded connection.
According to the invention, the windshield cross member is produced as a composite component made of an elongated aluminum beam having steel plate adapter parts that extend the aluminum beam at the ends thereof but are short in comparison to the overall beam length, and the steel plate adapter parts are connected to the associated A-pillar inner steel plate by means of the welded connection and to the aluminum beam by means of a riveted connection.
Japan — An object of this invention is to effectively improve the joint strength upon joining dissimilar metal plates by combining adhesion using an adhesive and spot welding. The joining method includes a step of lapping the aluminum alloy plate and the plated steel plate via adhesive, a pre-heating step of clamping both metal plates lapped in the lapping step between a pair of electrodes for spot welding and applying pressure thereto, and applying a current between the pair of electrodes, a cooling step of pressurizing both metal plates at a pressing force higher than that at the start of the pre-heating step in a state where conduction between the electrodes is stopped, and continuing this pressurization over a predetermined cooling time, and a welding step of pressurizing both metal plates at a pressing force higher than that at the start of the pre-heating step, and welding both of the metal plates by applying a current higher than the conduction current value in the pre-heating step between the pair of electrodes.
Japan — Provided is a joint product of a steel product and an aluminum material, the joint product being formed by joining the steel product having a sheet thickness t 1 of 0. Japan — The invention provides a structural member of different materials having no different-material-bonded part between aluminum alloy material and steel material to be assembled.
The structural member of different materials comprised of steel and aluminum alloy includes a first structural member including steel, and a second structural member having a part including steel and a part including aluminum alloy, the part including steel and the part including aluminum alloy being bonded by different-material bonding.
The first structural member and the second structural member are bonded together only by bonding of steels between the part including steel of the second structural member and the first structural member.
Japan — The object of the present invention is to provide a steel material for dissimilar metal joining, a joined body of dissimilar metals and a process for joining dissimilar metal materials, which are small in restriction such as application condition of spot welding, have excellent broad utility and, at the same time, have no inhibition of reliability in joining due to generation of a brittle intermetallic compound at a joining part, and have a joined part having high joining strength.
A joined body of dissimilar metals which is produced by joining a steel material and an aluminum alloy material, wherein the steel material to be joined has a specific composition and is specified in the compositions of outer surface oxide layer and inner oxide layer and the aluminum alloy material to be joined is an Al-Mg-base or Al-Zn-Mg-base aluminum alloy having a specific composition.
In the joined body of dissimilar metals, a content of Fe at a joint interface on the aluminum alloy material side is regulated, and a reaction layer of Fe and Al is formed at the joint interface of the joined body of dissimilar metals. I think the problem is aluminium is highly conductive, less resistance so no heat is generated, therefore more power is needed. You can cheat by putting a scrap of steel each side of the aluminium panels to be welded. The steel increases resistance and breaks away after welding.
I've done this a couple of times with my ancient single phase spot welder. Gofannon , Apr 7, Joined: Jan 25, Posts: Profile Page. What process does Ford use for building their aluminum body pickups? Joined: Jul 7, Posts: Profile Page. YES, you can spot weld ali with single phase spot welder.. Take 2 pieces of 22g stainless steel put one piece either side of the ali that your spot welding, and run the heat through the sandwich, your done, you will have a strong spot weld holding the two pieces of ali together, Now all you have to do is go to work and impress your boss Dont ask me how it works, its obviously physics..
Joined: Nov 23, Posts: 5, Profile Page. Joined: Nov 11, Posts: 25, Profile Page. At 21 years old there's lots left to learn about this world. They can only teach so much within 4 walls and your childhood home of 4 walls shouldn't let much of the world in. Getting out in the mix of things will expose one to how things really work.
For every 10 electricians you may ever need at home or school 1 will be able to wire and do industrial work. Most could tell you at least tell you something about 3phase power even if it's just that they don't do that work. You can find 3ph power anywhere there is industrial business and most commercial establishments. You can make your own 3 phase power easily however it's not the most efficient use of power. There's lots of industrial equipment for sale relatively cheap because it requires 3ph power.
Building a "rotary phase converter" should be part of the 8th grade science curriculum. Simply Spinning an electrical motor will create electricity, using a single phase motor connected to power to spin a 3phase motor will create 3phase electricity.
And wherever there is 3phase power there is also 1phase. You should be able to verify your sources before accepting what they say. That article seems like it was written by someone who doesn't know but parroted other sources.
Joined: Dec 6, Posts: Profile Page. Not sure about spot welding aluminum but I have been melting aluminum in a single phase electric kiln in my garage all week. Joined: Oct 10, Posts: Profile Page. I have a little welding shop with single phase but a lot of the farmers around me have 3 phase for irrigation I live in rural montana and 3 phase is pretty common.
Jerrybigbird , Apr 7, Joined: May 16, Posts: 5, Profile Page. I got a real good deal on a floor model drill press free. The only problem is that the motor was three phase and I only have single phase in my shop.
I investigated my alternatives changing motors, rotary converters, etc. It's a little box about 2" X 3" X 6". I installed it and it works fine. It has the additional capabilities of "soft-start", "soft-stop", speed control and reversing the rotation I haven't figured out how to use that yet, mainly because I don't need it. It has one big disadvantage; it looses a lot of power in the conversion. For commercial quality welds on 1. While ac power supplies can be used for welding aluminium alloys, inverter DC power supplies have been suggested as providing greater control of the short time welding pulse, and thus improved weldability.
It should be noted that with DC supplies, that there is a marked polarity effect. Nugget growth is offset slightly towards the positive electrode and this can be used to advantage when welding dissimilar thicknesses, by having the thinner sheet on the positive side.
In addition, the positive electrode is subjected to faster wear than the negative one. DC power supplies generally provide a more efficient use of the mains power at the high welding currents required.
Weld splash can be detrimental to weld quality and should be avoided. Some nugget porosity or cracking can occur, especially in sensitive alloy types. These flaws do not normally influence weld strength significantly, provided that normal plug button fracture occurs on testing. Dual force schedules are needed for high quality welds where control of nugget flaws is required. When comparing similar thickness materials, the static and fatigue shear strengths of aluminium alloy spot welds are about one third the value of steel welds depending on the alloy type.
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