Wɔde kɔbere–aluminum nkwaa di dwuma kɛse wɔ ahoɔden a wɔkora so, anyinam ahoɔden kar, batere, ne ahoɔden kyekyɛ nneɛma mu. Kɔbere ma anyinam ahoɔden tumi fa mu yiye, bere a aluminium ma emu duru sua na ɛho ka sua. Enti saa nneɛma abien yi a wɔaka abom no abɛyɛ ano aduru a wɔtaa de di dwuma wɔ batere busbars, tabs, ne ahoɔden a wɔkora so nkitahodi ahorow mu.
Capacitor discharge spot welding mfiri ahorowwɔtaa de di dwuma ma kɔbere–aluminum nkabom efisɛ wotumi de anyinam ahoɔden a ɛkorɔn yiye ma wɔ bere tiaa bi mu, na ɛde ɔhyew a ɛwɔ mpɔtam hɔ ne beae ketewaa bi a ɔhyew-ka ba. Ɛmfa ho mfaso horow yi no, wɔn a wɔyɛ nneɛma pii da so ara hyia nsɛm te sɛ nsu a wɔde petepete nneɛma so dodo, weld no ani a ayɛ tuntum, ne weld no su a ɛnkɔ so pɛpɛɛpɛ.
Saa ɔhaw ahorow yi nnyɛ sɛ ɛka nneɛma no hwɛbea nko na mmom ebetumi atew anyinam ahoɔden a ɛkɔ so no so, ama mfiri ahoɔden ayɛ mmerɛw, na asɛe ahotoso a ɛwɔ hɔ bere tenten. Wɔ mmeae a wɔyɛ nneɛma ankasa dodow no ara mu no, ɛntaa mma sɛ ade biako pɛ na ɛde sintɔ a ɛte saa ba. Mmom no, wɔtaa fi nkɛntɛnso a wɔaka abom a efi welding parameters, nneɛma tebea, electrode adwumayɛ, nnwinnade a ɛne ne ho hyia, ne adwumayɛ tebea mu ba.
Afã horow a edidi so yi hwehwɛ nneɛma atitiriw anum a ɛde spatter ne weld kɔla sesa wɔkɔbere–aluminum a wɔde yɛ weldingna wɔde nyansahyɛ ahorow a mfaso wɔ so a wobetumi de adi dwuma tẽẽ wɔ mmeae a wɔyɛ nneɛma ma.
Imbalance wɔ Welding Ahoɔden Parameters mu
Wɔ kɔbere–aluminum welding mu no, ahoɔden sohwɛ yɛ nneɛma a ɛho hia sen biara a ɛka spatter formation ne weld kɔla a ɛsakra nyinaa no mu biako. Kɔbere wɔ ɔhyew a ɛkɔ soro kɛse sen aluminium, bere a aluminium nwene sua koraa (bɛyɛ digrii 660 ). Sɛ wɔanhwɛ ahoɔden a wɔde ba no so yiye a, ɛnyɛ den sɛ ɔhyew a ɛboro so wɔ baabiara betumi aba, na ɛde apetepete ne oxidation a emu yɛ den aba.
1.Excessive Discharge Ahoɔden anaa Current
Sɛ wɔde discharge ahoɔden anaa peak current a capacitor discharge welder de si hɔ no kɔ soro dodo a, weld zone no hyew kɔ soro ntɛmntɛm koraa. Aluminium taa nwene ntɛmntɛm sen kɔbere, bere a kɔbere ma ɔhyew no kɔ mmeae a atwa ho ahyia no bere koro mu. Saa kari a ɛnkari pɛ yi ma ɔtare a ayow a entumi nnyina, na ɛma wɔpam dade a ayow wɔ nhyɛso ase, na ɛma wɔde petepete a wotumi hu ba.
Bere koro no ara mu no, ɔhyew a ɛkɔ soro ma oxidation reactions yɛ ntɛmntɛm wɔ kɔbere–aluminum ntam, na ɛma weld no ani kɔla sesa tuntum anaa tuntum.
Wɔakyerɛ nsɛm a wɔtaa de gyina hɔ ma kɔbere–aluminum kɛse a wɔaka abom a wɔtaa de di dwuma wɔ ase ha:
| Nneɛma a Wɔde Yɛ Adwuma | Ahoɔden a Wɔkamfo Kyerɛ | Peak Current a Ɛwɔ Hɔ | Weld Bere a Wɔtaa Yɛ |
|---|---|---|---|
| 0.5mm Cu + 0.5mm Al | 3000–4500 J | 25–35 kA na ɛwɔ hɔ | 3–8 ms na ɛwɔ hɔ |
| 1.0mm Cu + 1.0mm Al | 4500–6500 J | 35–50 kA na ɛwɔ hɔ | 6–12 ms na ɛwɔ hɔ |
| 1.5mm Cu + 1.5mm Al | 6500–8000 J | 45–60 kA na ɛwɔ hɔ | 8–20 ms na ɛwɔ hɔ |
Wɔ nneɛma a wɔyɛ mu no, ɛyɛ papa sɛ wobefi ase de ahoɔden a ɛba fam na ama akɔ soro nkakrankakra denam sɔhwɛ welding so sen sɛ wɔbɛyɛ nsakrae akɛse wɔ anammɔn biako mu.
2.Bere a Wɔde Fi Afiri Mu Ntraso
Ɛwom sɛ capacitor discharge welding taa hwehwɛ sɛ wɔde weld bere tiaa bi di dwuma de, nanso bere a wɔde fi mu a wɔtrɛw mu wɔ ɔkwan a ɛmfata so no da so ara betumi ama ɔhyew a ɛboaboa ano dodo aba. Sɛ weld interface no kɔ so tra ɔhyew a ɛkorɔn mu kyɛ dodo a, beae a ayɛ hyew no trɛw dodo na ɔhyew a ɛboro so betumi aba.
Saa tebea yi ma sɛnea ɛbɛyɛ yiye sɛ nsu bɛpetepete no yɛ kɛse na ɛma oxidation yɛ ntɛmntɛm, na ɛma weld no ani yɛ tuntum.
Wɔ kɔbere–aluminum dwumadie dodoɔ no ara mu no, ahigh-mprempren, bere tiaa-bere kwanno yɛ nea wɔpɛ efisɛ ɛma weld nugget a ɛyɛ den bere a ɛtew ɔhyew a ɛho nhia a ɛba no so.
3.Uneven Energy Output anaasɛ Abnormal Asorɔkye ahorow
Sɛ tumi a wɔde ma no yɛ nea entumi nnyina esiane capacitor dedaw anaasɛ control system no asɛe nti a, mprempren asorɔkye no betumi asakra bere a wɔreyɛ welding no. Saa a entumi nnyina yi ma ɔhyew no nkyekyɛ pɛpɛɛpɛ wɔ beae a wɔde weld no yɛ no.
Ne saa nti, ebia mmeae bi benya fusion a ɛnnɔɔso bere a afoforo nso yɛ hyew dodo, na ɛde sptter ne weld coloration a ɛnkɔ so pɛpɛɛpɛ bɛba.
Wɔ high-volume production tebea horow mu no, capacitor tumi a ɛso tew boro bɛyɛ 10% betumi aka weld consistency kɛse. Enti wɔkamfo kyerɛ sɛ daa nhwehwɛmu a wɔyɛ wɔ capacitor adwumayɛ ne output waveform stability ho.
Kɔbere ne Aluminium Ahosiesie a Ɛnyɛ Nea Ɛfata
Wɔ nneɛma pii a wɔyɛ mu no, ɛnyɛ nnwinnade anohyeto na ɛde weld sintɔ ba na mmom esiane sɛnea wɔansiesie nneɛma a ɛwɔ soro no yiye nti. Kɔbere ne aluminium a ɛwɔ soro no fi awosu mu yɛ oxide ntoatoaso bere a ɛda mframa mu no, na sɛ wɔannyi saa nsensanee yi afi hɔ yiye a, ɛyɛ den sɛ wɔde nnwinnade a ɛkɔ anim mpo hyehyɛ welding a ɛyɛ den.
1.Incomplete Yi Oxide Layers
Kɔbere ne aluminium nyinaa yɛ oxide sini ahorow ntɛmntɛm wɔ mframa mu. Aluminium oxide titiriw no, ne hyew bɛyɛ digrii 2050 , a ɛkorɔn kɛse sen aluminium ankasa de.
Bere a wɔreyɛ welding no, oxide layer no nwene ntɛm na mmom esiw mprempren nsu a ɛsen no kwan. Saa ahoɔden a ɛko tia yi ma localized arcing ba, a ɛma spatter na ɛboa ma weld no ani yɛ sum.
Wɔtaa kamfo akwan a wɔfa so siesie mfiri te sɛ abrasive polishing anaa stainless-steel brushing. Ɛsɛ sɛ bere a ɛda ahotew ne welding ntam no yɛ nea eye sen biara sɛ ɛyɛ nea ennu nnɔnhwerew anan na ama re-oxidation no ayɛ ketewaa bi.
2.Ngo, Mfutuma, anaa Efĩ a Aka
Bere a wɔde mfiri reyɛ adwuma, de asie, anaa wɔredi ho dwuma no, kɔbere ne aluminium a ɛwɔ soro no taa boaboa nsu a wɔde twa, srade, anaa efĩ a ɛwɔ mframa mu ano. Sɛ saa nneɛma yi kɔ so tra soro a, ebetumi ahyew anaasɛ ayɛ carbon bere a wɔreyɛ welding no.
Saa adeyɛ yi betumi ama nneɛma tuntum a aka ne mframa a ɛwɔ nipadua no mu aba, na ɛde kɔla a wotumi sesa na ebetumi atew anyinam ahoɔden a ɛkɔ mu no so.
Wɔkamfo kyerɛ kɛse sɛ wɔmfa mfiridwuma mu nsa anaa acetone nhohoro ho ansa na wɔayɛ welding na ama wɔahwɛ ahu sɛ nneɛma a ɛwɔ soro no bɛyɛ pɛpɛɛpɛ.
3.Improper Surface Roughness a ɛyɛ mmerɛw
Nneɛma a ɛwɔ soro a ɛyɛ mmerɛw no di dwuma titiriw wɔ hwɛ a ɛma anyinam ahoɔden di nkitaho a ɛyɛ den no mu. Nneɛma a ɛyɛ mmerɛw dodo no taa kyere oxide nneɛma nketenkete ne efĩ, bere a nneɛma a ɛyɛ torotoro dodo no betumi atew baabi a ɛne ne ho di nkitaho yiye no so.
Tebea abien no nyinaa betumi ama mprempren nkyekyɛmu a ɛnteɛ ne ɔhyew a ɛboro so wɔ mpɔtam hɔ.
Wɔ dodow no ara kɔbere–aluminum welding applications, a soro roughness range ofRa 0.8–1.6 μm na ɛwɔ hɔwobu no sɛ ɛfata.
Electrode Nhyehyɛe Ho Nsɛm
Electrode nhyehyɛe no di dwuma abien wɔ welding mu denam current a ɛkɔ ne mfiri ahoɔden a ɛde di dwuma no so. Deviation biara wɔ electrode tebea mu betumi aka weld pintinn kɛse.
1.Incompatible Electrode Nneɛma anaasɛ Ɛboro so Wear
Electrode nneɛma a wɔpaw no yiye anaasɛ wɔde di dwuma bere tenten a wonsiesie no betumi ama electrode no asɛe anaasɛ asɛe. Saa nsakrae yi sesa mprempren density kyekyɛ na ebetumi ama localized overheating aba.
Nneɛma a wɔtaa de yɛ electrode no bi ne:
| Electrode Nneɛma a Wɔde Yɛ Adwuma | Esu | Nnwuma a Wɔtaa De Di Dwuma |
|---|---|---|
| CuCrZr na ɛyɛ | Conductivity a ɛkorɔn ne wear resistance | Kɔbere–aluminum welding a wɔde di dwuma wɔ ɔkwan a ɛkɔ akyiri so |
| WCu | Ɔhyew a ɛkorɔn-a ɛko tia a ɛkyɛn so | High-ahoɔden welding |
| Kɔbere a Ɛho Tew | Conductivity a ɛkorɔn nanso ɛtra hɔ kyɛ a ɛba fam | Hann-asɛdeɛ dwumadie |
Ɛsɛ sɛ wɔtaa hwɛ electrode ahorow mu bere biara3000–5000 weld kyinhyia, a egyina dodow a wɔyɛ so.
2.Electrode Force a ɛnnɔɔso anaasɛ ɛnyɛ pɛpɛɛpɛ
Sɛ electrode ahoɔden nnɔɔso a, ebia nsonsonoe nketenkete bɛda nneɛma a wɔde yɛ adwuma no ntam. Bere a nsu retu no, saa nsonsonoe yi betumi ama arcing aba, na ama nsu a ɛpetepete kɛse aba.
Bere koro no ara mu no, nkitahodi a enye ma localized resistance yɛ kɛse, na ɛma ɔhyew a ɛboro so yɛ ntɛmntɛm na ɛma weld kɔla sesa.
Wɔ kɔbere–aluminum dwumadie dodoɔ no ara mu no, electrode ahoɔden taa hwe ase wɔ range of200–600 N, a egyina nneɛma a wɔde yɛ adwuma no mu duru so.
3.Poor Electrode Cooling anaasɛ Surface Efĩ
Sɛ onwini nhyehyɛe no antumi anhwɛ ɔhyew so yiye a, electrode no hyew kɔ soro nkakrankakra. Saa tebea yi ma asiane a ɛwɔ hɔ sɛ ɛbɛbata na dade bɛbata electrode no ani no yɛ kɛse.
Wɔ weld a edi hɔ mu no, saa nkae yi betumi ahyew na ayɛ carbon a ɛwɔ hɔ, na ama weld no kɔla asesa.
Tebea horow a wɔkamfo kyerɛ sɛ ɛma onwini no bi ne:
- Nsuo a ɛma onwini hyew: 20–30 digrii
- Nsuo a ɛma onwini no sen: Ɛboro anaasɛ ɛne 4 L/min yɛ pɛ
Mismatch Between Adeyɛ ne Nnwinnade a Wɔde Yɛ Adwuma
Sɛ mpo wɔayɛ nsakraeɛ wɔ parameters mu yie a, weld sintɔ bɛda so ara aba sɛ nnwinnadeɛ nhyehyɛɛ ne application ahwehwɛdeɛ no nhyia a.
1.Improper Electrode Contact Area anaa Nsusuwii
Sɛ electrode geometry ne adwuma no nhyehyɛe nhyia a, mprempren nkyekyɛmu no bɛyɛ nea ɛnteɛ. Mmeae a ɛsõ dodo a ɛne ne ho di nkitaho no brɛ mprempren density ase, bere a mmeae nketewa dodo no ma asiane a ɛwɔ hɔ sɛ ɛhɔ bɛyɛ hyew dodo no yɛ kɛse.
Enti ɛsɛ sɛ electrode nhyehyɛe a ɛfata gyina nneɛma no kɛse ne weld kɛse a wɔhwehwɛ so.
2.Lack of Shielding Gas Mmoa
Wɔ dwumadie a ɛhwehwɛ sɛ ɔfasuo yɛ papa mu no, oxygen a wɔde hyɛ mu bere a wɔreyɛ welding no betumi ama oxidation reactions ayɛ ntɛmntɛm.
Nhwehwɛmu ahorow kyerɛ sɛ sɛ wɔde argon shielding gas di dwuma a, ebetumi atew weld surface oxidation so bɛyɛ30–50%, a ɛma ne honam ani hwɛbea ne nea ɛkɔ so daa no tu mpɔn.
3.Equipment Mpanyinyɛ anaasɛ Component Failure
Bere kɔ so no, nneɛma te sɛ capacitors, control modules, ne cooling systems betumi asɛe. Saa ɔsɛe yi ma nhyehyɛe no nyinaa a ɛgyina pintinn no so tew.
Nnwinnade a wɔayɛ adwuma amaMfeɛ 3–5ɛsɛ sɛ wɔyɛ nhwehwɛmu wɔ nhyehyɛe kwan so de hwɛ sɛnea wɔyɛ adwuma no.
Adwumayɛ ne Nneɛma a Atwa Yɛn Ho Ahyia
Adwumayɛ ho nsɛm nketenkete a ɛte sɛ nea ɛyɛ nketenkete nso betumi anya weld su so nkɛntɛnso kɛse.
1.Poor Adwumayɛbea Alignment anaa Gaps
Sɛ wɔamfa kɔbere ne aluminium afã horow no anhyɛ mu denneennen a, anyinam ahoɔden a ɛyɛ ahinanan betumi aba bere a wɔretu no, na ɛde apete kɛse aba na ayɛ hyew dodo wɔ baabiara.
Hwɛ a wobɛhwɛ sɛ fit-up yiye ansa na woayɛ welding no ho hia.
2.Abnormal Ɔhyew anaa Nsuo Tebea
Nneɛma a atwa yɛn ho ahyia a ɛhɔ yɛ nwini kɛse no boa ma nsu a ɛtwetwe wɔ nneɛma no ani, na ɛma oxidation yɛ ntɛmntɛm.
Nneɛma a atwa yɛn ho ahyia tebea horow a wɔkamfo kyerɛ no bi ne:
- Ɔhyew: 15–30 digrii
- Nsuo a ɛyɛ nwini: 40%–70%
3.Lack of Daa Electrode Nsiesiei
Wɔ mmeae a wɔyɛ nneɛma a ɛkɔ so no, sɛ wɔantumi anhwɛ electrode ahorow so a, ebetumi asɛe welding adwumayɛ nkakrankakra.
Wɔkamfo nhyehyɛe a wɔde bɛhwɛ nneɛma mu daa, da biara da ahotew, ne nneɛma a asɛe a wɔbɛsesa bere ne bere mu no kyerɛ denneennen.
FAQ
Asɛmmisa: Dɛn na ɛsɛ sɛ wodi kan hwɛ mu bere a nsu a wɔde petepete so no boro so no?
A: Ɛsɛ sɛ wodi kan hwɛ ahoɔden nhyehyɛe mu, titiriw ahoɔden a wɔde fi mu ne bere a wɔde yɛ weld, efisɛ ɔhyew a ɛboro so a wɔde ba no yɛ nneɛma a ɛtaa de ba no mu biako.
Asɛmmisa: So weld kɔla a ɛsakra no kyerɛ sɛ weld no adi huammɔ bere nyinaa?
A: Ɛnyɛ nea ɛho hia, nanso kɔla a ɛsakra kɛse taa kyerɛ sɛ ɛyɛ oxidation dodo na ebetumi aka ahotoso a ɛwɔ hɔ bere tenten-.
Asɛmmisa: Mpɛn ahe na ɛsɛ sɛ wɔhwɛ electrode ahorow so?
A: Wɔtaa kamfo kyerɛ sɛ wɔnyɛ nhwehwɛmu biara3000–5000 weld kyinhyia, a egyina tebea horow a wɔyɛ no so.
Asɛmmisa: Dɛn nti na parameters a ɛyɛ pɛ ma ɛsono nea efi mu ba?
A: Nsonsonoe a ɛwɔ soro tebea, electrode wear, ne nneɛma a atwa yɛn ho ahyia a ɛyɛ nwini mu betumi aka welding adwumayɛ kɛse.
Awie
Sɛ wɔtew nsu a ɛpetepete so na wosiw weld kɔla a ɛsakra wɔ kɔbere–aluminum welding mu ano a, ɛhwehwɛ sɛ wɔyɛ nhyehyɛe a ɛyɛ nhyehyɛe sen sɛ wɔbɛyɛ nsakrae a atew ne ho. Stable welding aba gyina ahoɔden parameters a ɛkari pɛ, ɔfasu ahosiesie a ɛfata, electrode adwumayɛ a wotumi de ho to so, nnwinnade nhyehyɛe a ɛfata, ne adwumayɛ tebea horow a wɔahyɛ so.
Wɔ mmeae a wɔyɛ nneɛma a mfaso wɔ so no, nhyehyɛe a wɔde di dwuma daa a wɔde ka ho ne nsiesie a wɔyɛ no daa no ma weld no tu mpɔn kɛse na ɛtew nsakrae a ɛba nneɛma a wɔyɛ so no so. Bio nso, nnwinnade a wɔpaw a wɔhwɛ ahoɔden so pɛpɛɛpɛ, onwini nhyehyɛe a etu mpɔn, ne mfiri a ɛyɛ adwuma a ɛyɛ den no di dwuma titiriw wɔ kɔbere–aluminum nkwaa a wotumi de ho to so a wobenya mu.
Wɔ nnwuma te sɛ ahoɔden a wɔkora so, batere a wɔyɛ, ne anyinam ahoɔden kar mu no, ɛnyɛ sɛnea weld gyina pintinn no yɛ asɛm a ɛfa sɛnea ɛte nko na mmom ɛyɛ ade titiriw a ɛka anyinam ahoɔden adwumayɛ ne bere tenten-adwuma mu ahobammɔ nso. Nneɛma a wɔyɛ no yiye a ɛkɔ so ne nsiesie ho nneyɛe a wɔde nteɛso yɛ da so ara ho hia na ama wɔanya adwumayɛ a ɛkorɔn ne nneɛma a wotumi de ho to so no nyinaa.
