Mass production welding of die-cast aluminium alloys by electron beam
This contribution presents the solution of technological aspects in mass production of die-cast aluminium alloys as well as the design of new modules necessary for successful dealing with production. The welded parts are made of near eutectic aluminium alloy AlSi10Mg(Fe) / EN AC-43400 by high pressure die-casting process. Materials by its chemical composition and narrow solidification range do not represents significant problem from weldability point of view. Major problem is material contamination caused by the die-casting process. Several procedures were proposed to eliminate the problem of reduced weldability. Except for technological problems this contribution presents the concept design of mass production welding machine which is based upon experiences of welding process optimization. Special attention is payed to design of welding machine modules such as discharge protection module and module for online monitoring and recording welding process parameters. Application of discharge protection module increase welding process stability and allow prolongation the electron gun maintenance time. Module for online monitoring and recording allows implementation of Quality Management processes required by automotive industry.