基于电阻点焊过程与形貌的飞溅成因分析及控制方法  

Analysis and control methods of spatter based on resistance spot welding process and morphology

作　　者：董波 郭东栋[1] 邹尚博 姜宗睿 Dong Bo;Guo Dongdong;Zou Shangbo;Jiang Zongrui(Beijing Benz Automobile Co.,Ltd.,Beijing 100176,China)

机构地区：[1]北京奔驰汽车有限公司,北京100176

出　　处：《焊接》2024年第8期69-74,80,共7页Welding & Joining

摘　　要：【目的】在汽车白车身制造生产过程中,电阻点焊是板件连接的主要焊接工艺,但电阻点焊焊接过程中焊渣飞溅对白车身焊接质量影响较大,还会导致设备故障等问题,进而增加返修成本并降低生产效率。因此,该文对降低电阻点焊白车身的飞溅成因分析与控制方法展开研究。【方法】提出了一种飞溅成因分析与控制方法的操作流程,从多维度分析焊接过程与焊接形貌,进而针对性地实施措施,并在实际生产中验证飞溅成因分析与控制方法的操作流程。【结果】在验证过程中。通过对焊装车间飞溅率较高的工位基于分析结果进行优化,使得车间整体飞溅率由14%降低至6%,飞溅率低于优化前50%,有效减少预打磨工位的工作量和飞溅引起的故障率。【结论】飞溅成因分析与控制方法的理论体系保证了白车身焊接质量,提高了生产效率,并为后续工作提供思路指导与经验借鉴。焊接飞溅率是焊装车间主要控制指标之一,在生产过程中还需要不断监测、调整和保持,从而制定更有效的标准流程,减少飞溅对白车身质量的影响。[Objective]Resistance spot welding is the major welding technology of plate connection during vehicle body-in-white production.However,during the resistance spot welding process,the spatter of welding slag has a significant impact on the welding quality of Body-inwhite,and can also cause equipment failures and other problems,thereby increasing repair costs and reducing production efficiency.Therefore,this article conducts research on the analysis and control methods of the causes of spatter in resistance spot welding of body-in-white.[Methods]A set of operational procedures for analyzing and controlling the causes of spatter has been proposed,which analyzes the welding process and welding morphology from multiple dimensions,and then exactly implements targeted measures.The operational procedures for analyzing causes and controlling methods of spatter have been verified in actual production.[Results]During the verification process,optimization was carried out on the workstations with high spatter rates in the welding based on the analysis results,resulting in a reduction in the overall spatter rate from 14%to 6%,with spatter rate being over 50%lower than before optimization,effectively reducing the workload of the pre polishing workstations and the failure rate caused by spatter.[Conclusion]This work ensures the body-in-white welding quality and improves the produce efficiency.It provides the clear work guideline and experience insight for the follow-up spatter control.The welding spatter rate is one of the main control indicators of the welding workshop,and it should be continuously monitored,adjusted and maintained in the production process,and an effective standard process should be formulated to effectively control the spatter and reduce the impact of the spatter on the quality of the body-in-white.

关 键 词：电阻点焊 飞溅缺陷 过程分析 形貌分析 控制方法 

分 类 号：TG408[金属学及工艺—焊接]