IWSL’s New Method Permits Selectable Weld Sizes and Strengths Of Aluminum Alloys
Common Issues With Aluminum Alloy Spot Welds:
- Spot sizes are limited by sheet thicknesses. For example, for spot welded sheets of thickness 1.6 mm each, the weld size is limited to about 8 mm.
- Shear strengths are typically limited to around 550 to 640 Kilogram Force (1200 to 1400 pound force) to failure in a shear test
- Efforts to increase weld size to increase strength result in electrode-to-metal interfaces becoming too hot and the weld process becomes unstable
- Photo on the right shows a typical weld interface failure in the shear test
This shows a typical weld interface failure in the shear test
Innovative Weld Solutions Achieves “The Impossible”:
- Spot sizes are not limited by sheet thicknesses. With our patented weld process and technology, welds of up to 12mm diameter are accomplished.
- Shear strengths are approximately 2X higher than conventional welds
- Weld temperatures are kept low, which avoids compromising integrity of the material
- Productivity increases 20X by increasing electrode life to >1000 spot welds between electrode dressing. Industry standards are approximately 50 welds between dressing, resulting in much greater down time.
- Higher quality cosmetic and aesthetic properties. Reduced post-weld finishing as a result
- Eliminate the need for 3/4″ edge requirement = Reduced/Eliminated waste material, Increased strength
With IWSL’s patented technology, strength of the aluminum weld exceeds all industry standards.
On the flat side of the weld, running a finger across the spot weld cannot locate it!! The weld is flat and smooth to the touch!
On the flat side of the weld, running a finger across the spot weld cannot locate it!! The weld is flat and smooth to the touch!
On the other side of the weld, there are outward indentations shaped like rivets. 450 Kg Force (1000 Pound Force)
12mm diameter weld in the same 1.6 mm thick 6061-T6 alloy sheet with a shear strength of nearly 900 Kg Force (2000 Pound Force). Spot welding industry standards currently only allow for welds of up to 9mm diameter.
Peel Tested FMRW spot weld made with IWSL’s welding method
IWSL’s New Spot Welding Method (Focused-Melt Resistance Welding (FMRW)) yields excellent microstructures; Even with large weld diameters, the outer layers are not melted and remain cosmetic!!