THIN METAL WELDING APPLICATIONS IN AUTOMOTIVE
As light weight trend is gaining momentum in Automotive industry, welding is facing more and more challenges from thinner plates, more various thickness and more applications of high-strength alloy and zinc-coated materials. But there are also requirements on spatter, deposition, gap filling and welding speed.
LINCOLN ELECTRIC® Welding Solutions：
LINCOLN ELECTRIC®’S has POWER WAVE® technology provides a verity of welding process to resolve common welding challenges of Automotive industry. Combining POWER WAVE® technology with LINCOLN ELECTRIC® JM® brand mig wire solution productivity can be improved while eliminating most of the welding challenges. LINCOLN’s Rapid Arc® and RAPID X® process can achieve a fast travel speed while reducing the spatter. Precision Pulse and RAPID Z® process can eliminate porosity levels at the highest travel speeds in zinc coated materials. STT® and AC-STT® performs very well on Gap Bridging on thin materials while reducing the spatter level.| Rapid Arc® | Fast travel speeds |
| RAPID X® | Fast Travel Speeds, Lower spatter |
| Precision Pulse™ | Puddle control |
| RAPID Z® | Lowest porosity levels, at the highest travel speeds |
| STT®, AC-STT® | Gap bridging, thin materials, Low Spatter |
LINCOLN ELECTRIC® Welding Solutions：
LINCOLN ELECTRIC®’S has POWER WAVE® technology provides a verity of welding process to resolve common welding challenges of Automotive industry. Combining POWER WAVE® technology with LINCOLN ELECTRIC® JM® brand mig wire solution productivity can be improved while eliminating most of the welding challenges. LINCOLN’s Rapid Arc® and RAPID X® process can achieve a fast travel speed while reducing the spatter. Precision Pulse and RAPID Z® process can eliminate porosity levels at the highest travel speeds in zinc coated materials. STT® and AC-STT® performs very well on Gap Bridging on thin materials while reducing the spatter level.| Rapid Arc® | Fast travel speeds |
| RAPID X® | Fast Travel Speeds, Lower spatter |
| Precision Pulse™ | Puddle control |
| RAPID Z® | Lowest porosity levels, at the highest travel speeds |
| STT®, AC-STT® | Gap bridging, thin materials, Low Spatter |
LINCOLN ELECTRIC® Welding Solutions：
LINCOLN ELECTRIC®’S has POWER WAVE® technology provides a verity of welding process to resolve common welding challenges of Automotive industry. Combining POWER WAVE® technology with LINCOLN ELECTRIC® JM® brand mig wire solution productivity can be improved while eliminating most of the welding challenges. LINCOLN’s Rapid Arc® and RAPID X® process can achieve a fast travel speed while reducing the spatter. Precision Pulse and RAPID Z® process can eliminate porosity levels at the highest travel speeds in zinc coated materials. STT® and AC-STT® performs very well on Gap Bridging on thin materials while reducing the spatter level.| Rapid Arc® | Fast travel speeds |
| RAPID X® | Fast Travel Speeds, Lower spatter |
| Precision Pulse™ | Puddle control |
| RAPID Z® | Lowest porosity levels, at the highest travel speeds |
| STT®, AC-STT® | Gap bridging, thin materials, Low Spatter |
LINCOLN ELECTRIC® Welding Solutions：
LINCOLN ELECTRIC®’S has POWER WAVE® technology provides a verity of welding process to resolve common welding challenges of Automotive industry. Combining POWER WAVE® technology with LINCOLN ELECTRIC® JM® brand mig wire solution productivity can be improved while eliminating most of the welding challenges. LINCOLN’s Rapid Arc® and RAPID X® process can achieve a fast travel speed while reducing the spatter. Precision Pulse and RAPID Z® process can eliminate porosity levels at the highest travel speeds in zinc coated materials. STT® and AC-STT® performs very well on Gap Bridging on thin materials while reducing the spatter level.| Rapid Arc® | Fast travel speeds |
| RAPID X® | Fast Travel Speeds, Lower spatter |
| Precision Pulse™ | Puddle control |
| RAPID Z® | Lowest porosity levels, at the highest travel speeds |
| STT®, AC-STT® | Gap bridging, thin materials, Low Spatter |
EXHAUST WELDING SOLUTION
LE Exhaust welding solution：
LINCOLN ELECTRIC® utilize combination of consumable and equipment technology to provide a complete solution for this application. With this unique solution, LE was able to reduce penetration to prevent burn through, while improving gap filling. Also this solution was able to increase travel speed while reducing the spatter which helped to increase productivity and reduce rework. LE was able to achieve 1.5 M/min travel speed with this combined solution.
Exhaust welding challenge
Exhaust pipe is mainly made from thin stainless metal sheet with regular thickness of 0.8-1.5 mm. It is hard to keep all workpieces identical so there are various gaps. Many of the joints are tube-in-tube type. Despite frequent burning-through, exhaust welding has strict requirements on spatter, weld width and amount of filling metal. Meanwhile, low rates of rework, high efficiency as well as high quality are also pursued.
Customer Application: Exhaust Tube to Resonator
Exhaust Tube to Resonator welding application consist of 1.2MM wall thickness on exterior resonator wall, 1.2MM wall thickness on insert (overall outer thickness of 2.4 MM), and finally 1.2MM wall thickness on inner tube. Welding this parts can be challenging. Common welding issues are gaps, burn though, spatter, and low productivity.
For this solution, LINCOLN® is using PRIMALLOY® metal core wire solution with LE POWER WAVE® equipment.
1. Welding consumable: PRIMALLOY® T-409Ti&439Ti&430LNb
Metal core wire can highly improve deposition, welding speed and lower the spatter
close to zero. On thin metal sheet, metal core wire has less burning through and better gap filling. Excellent fluidity contributes to decent appearance.
2. POWER WAVE® Technology: POWER WAVE® Process
**Provide description of each mode below.
| Weld Mode |
Gap Range（mm） | Travel Speed |
| STT® | 0-1.5 | Lowest |
| Precision Pulse | 0-1.2 | Medium |
| AC STT® | 0-1.5 | Medium |
|
Rapid-X™ |
0-1.2 |
Fastest |
Find the regional sales office or manufacturing factory, please click the button to go immediately, we will provide you the information you need as comprehensively as possible.