TRUCK AND TRAILER

Welding Aluminum Trailers can be complicated due materail handlling and welding of large components. Some of the other common isses are the part variation, aesthetic appearance of welds, spatter, and down time due to feeding issues. 

There are three componentas to Tanker trailer welding; Tank Seam welding, Circumferential Stiffener welding, and Undercarriage welding.  Parts fitup, heat input, spatter, apperance of welds and feeding issues are the common issues of welding Tanker trailers.

Lincoln Electric Solution:

  • Lincoln Electric has portable equipment and unique waveforms designed for Aluminum application to get best weld appearance and ease of use. 
  • Lincoln’s SuperGlaize alloys are optimized for smooth welding performance. 
  • Welding wire and equipment solution optimized for best feeding and provide a High deposition process solutions.
 
Trailers Tanker Tank Seam Automated MIG
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Butt Joint – 6.44mm – Single pass – 5xxx base material,5356 filler metal

Solution Benefit:

  • 18-76% increase in travel speed
  • consistent penetration
  • reduced heat input
  • increase deposition rate
  • Calc. based on a common travel speed of 17 IPM
Trailers Tankers Circumferential stiffener manual CC Pulse Mig
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T-Joint – 6.4mm 5xxx to 4.8mm 6xx ;

Single pass,5356 filler metal

 

Solution Benefits:

  • 76-88% increase in travel speed
  • consistent penetration
  • reduced heat input
  • Increased deposition rate
  • Calc. based on a common travel speed of 17 IPM 
Trailers Tankers Undercarriage manual CC Pulse Mig
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T-Joint – 6.4mm 5xxx to 9.5mm 6xxx ;

Single pass,5356 filler metal

 

Solution Benefits:

  • 47-64% increase in travel speed
  • consistent penetration
  • reduced heat input
  • Increased deposition rate
  • Calc. based on a common travel speed of 17 IPM 
POWER WAVE® TECHNOLOGY FOR ALUMINUM:

Power Wave® Technology:Speed and quality made possible with Power Wave

 Maximum weld speeds  : Minimum cycle times 
 Elimination of spatter  : Reduced rework
 Consisetent welds  : Adapts to varying weld joint and base material conditions
 Complete Process Control : Enable by supporting software tools;Weld Sequencer;Check Point® ;Weld Score® ;Power Wave® Utilities
 Power Wave®  Weld Processes: Pulse;CC Pulse;Power Mode;AC MIG;Pulse on Pulse

Power Wave® welding process

CC Pulse:

Graphic Description: 1. Pulse Ramp/ Peak; 2. Tailout; 3. Background; 4. Transition Current; 5. Frequency

Solution Benefits: more stable than conventional pulsed spray welding modes for aluminum; minimized arc 'flaring' or 'hunting', especially when using 5XXX filler alloys; more uniform than conventional CV welding.

Advantages: more consistent weld penetration; easier to use than conventional pulsed spray modes; used to troubleshoot feeding issues; preferred mode for 'whipping' or 'shuffling' technique.

 

Power Mode™

Power Mode™ Penetration Profile: 7/8’’ CTWD   5/8’’ CTWD

Output Characteristics: Power Mode™; Constant Current (CC); Constant Voltage (CV); Amperes - A; Volts - V

Solution Benefits: Power Mode™ uses energy (V x I = W) to regulate the arc length; adjusts the output current in real time by sensing actual power; better current stability than CV with spray transfer mode and aluminum welding.

Advantage: more consistent weld penetration; fewer fusion defects in welds; provides stable arc performance and less current fluctuation; recommended for large diameter welding wire.

AC Pulse

UltimArc™ control: The UltimArc™ control fine tunes the heat input into the plate. Increasing (+) the setting provides more heat into the weld puddle resulting in a more focused arc. Decreasing (-) the setting reduces heat direction into the puddle resulting in a less focused arc.

Solution benefits: ideal on material 0.8 mm - 3.0 mm; lower heat input

Advantage: less burn through on thin material results in no rework; reduced heat input minimizes HAZ; faster travel speeds improves overall productivity; reduces scrap by granting gap welding capabilities; improves cost-reduction on automated systems by further improving travel speeds.

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