ã€Abstract】 The application of friction stir welding (FSW) technology in domestic urban rail vehicles is briefly described. The main characteristics of 6005A hollow aluminum profiles and the main factors affecting the quality of friction stir welding are analyzed from the aspects of process manufacturing technology. Key control measures for the welding and rework of aluminum alloy 3.5mm hollow pair lap joints.
1 Overview
At present, in the aerospace, shipbuilding and other industries, friction stir welding technology has been applied, but in the field of rail transit, aluminum alloy friction stir welding technology is still in the initial stage of research. In 2010, the Guangzhou Metro Line 3 urban rail vehicle body developed by our company used the friction stir welding technology for the first time in China, which greatly broadened the welding technology of rail vehicles (see Figure 1).
Figure 1 The first rail transit body to use FSW
In the field of rail vehicles, the arc welding connection mode of aluminum alloy extruded profiles has become an important factor restricting the lightweight development of trains. The strength of the friction stir welded joint is better than that of the MIG welded joint, and the defect rate is low and the manufacturing cost is low. The use of FSW technology in the manufacture of rail vehicles will become the mainstream trend. FSW technology is promoted faster, but engineering application time is not long, so it is extremely important to improve the manufacturing level of FSW. This paper takes the welding of hollow aluminum profile 6005A of rail vehicle as an example to analyze the manufacturing process of FSW.
2. 6005A aluminum profile FSW process features
FSW is a new welding process. Compared with ordinary fusion welding, this is a solid plastic joining process. The high-speed rotating mixing head generates frictional heat, which causes the metal to reach a plastic molten state to form a weld joint. The FSW welding principle is shown in Figure 2.
Figure 2 FSW welding principle
In the application process of the rail vehicle engineering, the FSW process is mostly flat-type structure. The 6005A aluminum profile welding process of our company uses the pressure-sensing FSW equipment provided by Beijing Sai Foster Company (see Figure 3).
Figure 3 FSW welding equipment
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Please refer to the attachment for more details.
(According to the contents of the attachment) In the field of road vehicles, there are few researches on the repair technology of FSW welds of 6005A aluminum alloy. At present, there are two kinds of process realization measures in the rework technology: 1 The FSW is stirred again with reasonable welding parameters. 2 For the characteristics of aluminum alloy materials, the welding process is performed by a mature arc welding process. The FSW welds for the problem FSW welds need to be tested for the characteristics of the product and the application state. The repair welding with the arc welding process proves to be feasible in the relevant tests. Therefore, the FSW technology is reworked in the engineering of the 6005A aluminum profile. Technology still needs to be improved.
5 Conclusion
In the field of rail vehicles, the application of FSW technology for aluminum alloy 6005A hollow extrusion profiles is still in its infancy. To ensure the quality of aluminum alloy FSW in rail vehicles, it is necessary to improve the process in the manufacturing process and strengthen process control research, such as aluminum alloy parts. Pre-weld assembly, welding parameter verification, tooling adjustment, post-weld orthodontics, and defect handling.
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