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:
Butt Joint – 6.44mm – Single pass – 5xxx base material，5356 filler metal
Solution Benefit：
T-Joint – 6.4mm 5xxx to 4.8mm 6xx ；
Single pass，5356 filler metal
Solution Benefits：
T-Joint – 6.4mm 5xxx to 9.5mm 6xxx ；
Single pass，5356 filler metal
Solution Benefits：
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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