THIN METAL WELDING
EXHAUST WELDING

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.
Chassis
Interior
Axle/Wheels
Body-in-White
Welding Challenges
  • Variation in fit-up
  • Zinc Coated materials
  • Spatter
  • Thin materials
  • Faster travel 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. 
Welding Equipment Solution: Power Wave® Technology
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 Consumable solution:

Lincoln GMAW wire exhibit less contact tip wear and Superior feedability on High performance robotic applications.  Cast free or twist free packaging resulting in superior wire placement.  Lincoln’s strict QC retirement makes every coil runs the same resulting consistent welding performance.

Welding Challenges
  • Variation in fit-up
  • Zinc Coated materials
  • Spatter
  • Thin materials
  • Faster travel 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. 
Welding Equipment Solution: Power Wave® Technology
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 Consumable solution:

Lincoln GMAW wire exhibit less contact tip wear and Superior feedability on High performance robotic applications.  Cast free or twist free packaging resulting in superior wire placement.  Lincoln’s strict QC retirement makes every coil runs the same resulting consistent welding performance.

Welding Challenges
  • Variation in fit-up
  • Presence of gaps
  • Thin material
  • Fast travel 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. 
Welding Equipment Solution: Power Wave® Technology
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 Consumable solution:

Lincoln GMAW wire exhibit less contact tip wear and Superior feedability on High performance robotic applications.  Cast free or twist free packaging resulting in superior wire placement.  Lincoln’s strict QC retirement makes every coil runs the same resulting consistent welding performance.

Welding Challenges
  • Variation in fit-up
  • Presence of gaps
  • Thin material
  • Fast travel 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. 
Welding Equipment Solution: Power Wave® Technology
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 Consumable solution:

Lincoln GMAW wire exhibit less contact tip wear and Superior feedability on High performance robotic applications.  Cast free or twist free packaging resulting in superior wire placement.  Lincoln’s strict QC retirement makes every coil runs the same resulting consistent welding performance.

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

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