Unprecedented Welding Close to Sheet Edges of Aluminum Alloys
Common Issues with Aluminum Alloy Edge Spot Welds
How close to the edge of aluminum alloys can I weld?
- Resistance spot welding close to aluminum alloy sheet edges within 10mm is not considered possible
- The sheet edges are deformed and become very non-cosmetic
- There is much electrode indentation and reduction of thickness at the weld
- There is also much expulsion of weld metal at the weld interface through the sheet edges
- Weld electrodes pick up some molten aluminum and electrode life is not satisfactory
- Weld quality is also often questionable
- IWSL’s new FMRW spot welds close to the aluminum alloy sheet edges are very cosmetic
- No loss of thickness at the weld
- No bulging at the sheet edge
- Non-melted outer layers of the weld nuggets help maintain long electrode life in excess of 1000 welds between dressing operations
- No expulsion of weld metal at the weld interfaces for welds up to 3 mm from the edge
- Weld to weld distances closer than normally permitted and weld sizes larger than normally possible can be chosen by the designer without regard to the sheet thicknesses welded.