Under the high precision requirements of automobile gauges, how can the common welding defects of non-standard welding parts be prevented or repaired through process optimization?
Publish Time: 2025-04-15
In the field of automobile manufacturing, gauges are key tools to ensure the dimensional accuracy and assembly quality of parts, and their manufacturing precision requirements are extremely high. As an important part of automobile gauges, the welding quality of non-standard welding parts directly affects the overall performance and service life of the gauges. However, during the welding process, non-standard welding parts often have defects such as pores, cracks, and unfusion, which not only reduce the accuracy of the gauges, but also may cause safety hazards. Therefore, it is particularly important to prevent and repair these welding defects through process optimization.
The selection of welding process parameters has a decisive influence on the welding quality. In the manufacture of non-standard welding parts of automobile gauges, parameters such as welding current, voltage, and welding speed should be accurately adjusted according to the type, thickness, and welding position of the material. For example, for thin plate welding, a smaller welding current and a faster welding speed should be used to avoid burn-through and deformation; for thick plate welding, the welding current and welding time should be appropriately increased to ensure penetration.
The quality of welding materials is directly related to the occurrence of welding defects. Therefore, the procurement, storage and use of welding materials should be strictly controlled. Welding materials should be stored in a dry and ventilated environment to avoid moisture and contamination. Before use, the welding materials should be inspected and tested for performance to ensure that the materials meet the standard requirements.
Reasonable fixtures can effectively limit welding deformation and improve welding accuracy. In the manufacture of non-standard welding parts of automotive inspection fixtures, special fixtures should be designed according to the structural characteristics and welding requirements of the welded parts. The fixtures should have sufficient rigidity and precision to ensure the stability and positioning accuracy of the welded parts during the welding process.
Porosity is one of the common defects in the welding process, and its causes are mainly related to welding materials, welding processes and environmental factors. For the existing porosity defects, the method of repair welding can be used for repair. Before repair welding, the porosity part should be cleaned and polished to remove impurities and oxides. Then, select appropriate welding materials and process parameters for repair welding to ensure that the welded part is well integrated with the surrounding metal.
Cracks are the most serious type of welding defects, and their causes are complex and diverse. For crack defects that have already occurred, the cracks should be evaluated and located first to determine the nature and expansion of the cracks. Then, according to the severity and location of the cracks, choose the appropriate repair method. For shallow cracks, grinding and repair welding can be used for repair; for deep cracks, it may be necessary to repair them by digging or replacing welded parts.
Incomplete fusion refers to the phenomenon that part of the metal in the welded joint is not completely fused. The cause is mainly related to the welding process and welding materials. For the incomplete fusion defects that have already occurred, the defects should be cleaned and polished first to remove impurities and oxides in the unfused parts. Then, choose the appropriate welding materials and process parameters for repair welding to ensure that the welded parts are well fused with the surrounding metal.
