Single-wire pulsed MIG welding test was used on 6005A Aluminum alloy lap joints with CLOOS special welding robot.The microstructure,welding heat inputting,stress were comprehensively analyzed for post-welding cracks universal occurred on the weld toe.Sysweld software was used to simulating welding heat,welding temperature field and stress field.Results of test and simulation showed that,welding heat inputting excessive and welding angle inconsequence,which induced part heat concentrated was the essential causes of cracks on 6005A Aluminum alloy lap joints.Assembly gap cause stress concentration was an important induced factor in welding cracks expanding and extension.Welding cracks were effectively controlled through optimizing welding parameter,adjusting welding angle and enhancing assembly effect,which assure the quality of production.
It is easily to cause weld defects in the aluminium alloy welding process because of its nature.The weld defects including pores,cracks,fusion defects,etc..Weld defect will affect quality of products.While welding as one general connection method in the railway vehicle production,the weld joint is the weak and easy to destroyed part in aluminium alloy structure.So assurance the weld joint quality is one of key measure to ensure the safety of railway vehicle working.MIG welding is the main weld method in railway vehicle production by now.It will be introduced about reason analysis,damage,prevention measure and solving measures of the weld defects in this test according the production process.
