Changchun Railway Vehicle Co., Ltd. Shao Li
Changchun Railway Passenger Car Co., Ltd. (hereinafter referred to as Changke) is a national key research and development and manufacturing base for key backbone enterprises, railway passenger cars and urban rail passenger cars. With the development of R&D and manufacturing technology for railway passenger cars and urban rail passenger cars, the application of new welding technology has also developed by leaps and bounds. On the basis of the original carbon steel vehicles, Changke has developed a variety of new products such as aluminum alloy vehicles and stainless steel vehicles, and has formed scale production. This is inseparable from the development and application of new welding technology. The following is a brief introduction to the new welding technology for long-haul applications.
Application of new welding technology in the production of stainless steel car body Stainless steel vehicles have the characteristics of light weight, long service life, simple manufacturing process, no need for painting and low maintenance cost. The stainless steel used in rail vehicles is mainly austenitic stainless steel such as SUS304 and SUS301L. The steel structure of the car body has high strength and good rigidity, and it is easy to realize lightweight body. The car body steel structure is an all-welded steel and plate beam structure. Stainless steel car body production application welding processes are: spot welding, seam welding, laser welding, MIG welding, TIG welding, micro-beam plasma arc welding and manual arc welding.
MIG welding, TIG welding and microbeam plasma arc welding
MIG welding, TIG welding and micro-beam plasma arc welding are used in the production of stainless steel bodies, mainly manual welding and manual semi-automatic welding. The welding materials used were 308L and 309L, and the wire diameters were 1.0 mm and 2.0 mm. The shielding gas is an argon-oxygen mixture and argon. The welding equipment uses a digital inverter pulse power supply with a rated current of 350A.
3. Application of new welding technology in the production of aluminum alloy car body The aluminum alloy car body has light weight, corrosion resistance, good flatness and easy to manufacture complex curved car body. Therefore, it is welcomed by transportation companies and railway transportation departments in various cities around the world. The aluminum alloy body is not only used in urban rail vehicles, but also has irreplaceable characteristics in the manufacture of high-speed railway vehicles. Therefore, the foreground of aluminum alloy bodies very good. There are two main forms of aluminum alloy car body design structure, namely plate girder structure and closed hollow profile structure.
Aluminum alloy body welding Aluminum is one of the most difficult materials to weld in all metals. Good welding quality requires more capital for personnel training and equipment and tooling investment. The aluminum alloy body mainly uses the MIG welding process. In order to reduce personnel costs and ensure welding quality, the aluminum alloy body is more suitable for automatic welding. Aluminum alloy body welding is usually divided into automatic welding of the large parts of the car body and automatic welding of the total components. Automatic welding of large parts generally refers to the roofing of the roof, automatic welding of the floor, automatic welding of the side beams, automatic welding of the underframe and the roof and side walls. The total composition of automatic welding generally refers to the automatic welding of the side wall and the roof, side wall and chassis joint seam. In the welding of small parts, key components such as bolsters are often welded using robots. The investment in large-scale key welding equipment and equipment in the manufacture of aluminum alloy car body is a necessary condition for the manufacture of aluminum alloy car body.
4. New welding technology in the carbon steel body carbon steel body is the plate beam structure. The welding of carbon steel body mainly adopts gas shielded welding process, mainly manual welding and semi-automatic welding. The welding materials are ER44-8 and ER50-6, and the wire diameter is 1.2 mm. The shielding gas is an argon-carbon dioxide mixture. The welding equipment is rated at 500A or 350A. There is only one welding robot on the roof.
V. Application of new welding technology in the production of bogies
The bogie is welded and the bogie frame is composed of “H†type structure. The steel plate is made of S355J2G3 K20409 or 16MnR.
Welding mainly uses gas shielded welding processes, mainly automatic welding and semi-automatic welding. The welding materials are ER70S-6 and ER50-6, and the wire diameter is 1.2mm. The shielding gas is an argon-carbon dioxide mixture. The welding equipment is rated at 500A. The bogie is welded with 15 welding robots.
This article is based on the speech of Mr. Shao Li from Changchun Railway Vehicle Co., Ltd. at the 2nd China Welding and Cutting Market Forum.
This article has an excerpt. For more details, please pay attention to Mechanical Workers (Hot Processing) No. 8 of 2007.
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