Svetsaren nr 2. 2000 - Esab

Structural 2D weldingA large number of simplified generic frames have beenwelded and thoroughly examined and tested. In theframe, extruded aluminium profiles of AA6060-T6 alloywith a thickness of 2.0 and 3.0 mm have been used.All the welding has been performed robotically andturning units have been used to evaluate different weldingpositions, welding sequences and clamping principles(see the simulations in the following figure)Structural 3D weldingA concept study was originally started in order to evaluatethe production of aluminium space frames in theexisting S/V70 and S80 body shops. This involves therobotised welding (production like) of the aluminiumcar body structure in the existing Volvo pallet systems.The space frame structure and the pallet system are dividedinto floor, sides and roof frames/pallets which arepositioned, fixed and joined at a separate station calledMPF, Multi-Pallet Framing. See Figure 5 taken from thepilot building in a manual MPF station.Figure 2. Simulation results from welding access control indifferent welding positions.The majority of the joints were fillet joints but somebutt joints were also tested. See some typical crosssectionsin Figure 3. Note the pores in the welds and theoverfill of the butt joint. Pore formation can be kept toa minimum if the parts are washed and pickled just beforewelding. On the other hand, too complicated a pretreatmentprocess is costly.Figure 3. Typical cross-sections of a horizontal fillet weldand a flat butt joint.In order to achieve robust welding quality, buttjoints should be avoided, mainly because of their sensitivityto gaps. The synchronous welding of frames withtwo robots has also been tested.The recording of measurements over a large numberof distortion sensors, positioned over the genericframe, has shown that the overall distortion can be reducedby more than 50% when using symmetrical welding.In addition, even less distortion was achieved whenoptimal clamping and welding sequences were tested.See principal test set-up in the Figure 4.Figure 5. Rear view of the concept car in the manual MPFstation.This study involved many technical disciplines, suchas geometry assurance, surface preparation for joining,joining technology, manufacturing engineering and suitablesurface treatment for the paint shop. From a joiningperspective, evaluations were carried out in order tostudy the influence of:• Existing clamping and tolerance situation with hydroformedparts• Different welding sequences and welding positions• Different joint geometry designsA 3D joint of the A-pillar in a side palette is shown inFigure 6. It is important to have good joint preparationwith very low cutting tolerances in order to keep gapsizes to a minimum.Figure 6. Detailed study of a 3D MIG joint and the correspondingresult after welding.In parallel to the concept building, comprehensivework has been carried out in the field of equipment developmentand quality assurance. Different roboticfunctional packages and in-process monitoring systemshave been evaluated and these activities are still inprogress. Many activities are also on-going in the fieldof NDT (Non Destructive Testing).Figure 4. Principal test set-up for symmetrical welding ofgeneric frames.Laser welding of tailored blanks inaluminiumOver the years, the tailored blanking of steel sheets hasbecome more and more popular and today this method18 • Svetsaren nr 2 • 2000