Low Heat Input Welding for Advanced High-Strength Steel Wheels
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Solution Overview
Problem
Traditional welding technologies for manufacturing steel wheels, such as flash welding and MAG arc welding, result in high heat input, leading to cracks, reduced yield, and inferior weld quality, especially when working with high-strength steel grades above 590 MPa, limiting the material strength and fatigue lifetime of steel wheels.
Innovation Solution
A manufacturing method using low heat input welding technology, specifically cold metal transfer (CMT) or gas tungsten arc welding (GTAW/TIG), combined with a jig device for precise positioning and heat management, to produce advanced high-strength steel wheels with improved weld quality and reduced deformation, enabling the use of higher tensile strength materials like AHSS up to 980 MPa.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional flash welding or MAG arc welding is used to manufacture steel wheels, then the manufacturing process is fast and continuous production is achieved, but the heat input is high causing abnormal hardness, cracks, and reduced fatigue lifetime
Solution Approach 1:
The patent changes the welding parameters by switching from traditional MAG arc welding to cold metal transfer (CMT) welding technology. This parameter change reduces heat input significantly, preventing abnormal hardness and cracks in the heat-affected zone, thereby improving fatigue lifetime while maintaining manufacturing efficiency
Solution Approach 2:
The patent replaces the thermal welding process (MAG arc welding) with a cold welding process (CMT welding). This substitution eliminates the harmful thermal effects that cause cracks and hardness issues, while still achieving strong welds suitable for high-strength steel grades above 590 MPa
2Productivity
If traditional MAG arc welding is used with continuous wire feeding, then production efficiency is maintained, but the arc instability causes non-uniform hardness and increased spatter
Solution Approach 1:
The patent changes the welding method from MAG arc welding with continuous wire feeding to cold metal transfer (CMT) welding. This parameter change stabilizes the welding process, eliminates spatter, and ensures uniform weld quality without compromising production efficiency
Solution Approach 2:
The patent converts the potential harm of high heat input and arc instability into benefit by using CMT welding technology. This technology eliminates spatter and ensures uniform weld quality, reducing post-weld grinding operations and improving overall manufacturing precision
3Strength
If high-strength steel grades above 590 MPa are used for rims, then wheel strength is improved, but traditional welding causes abnormal hardness and cracks reducing yield
Solution Approach 1:
The patent replaces traditional thermal welding processes with cold metal transfer (CMT) welding. This substitution enables the use of high-strength steel grades above 590 MPa by eliminating the thermal effects that cause abnormal hardness and cracks, thereby improving both strength and manufacturability
Solution Approach 2:
The patent changes the welding temperature parameters by using cold metal transfer technology instead of traditional hot welding processes. This parameter change makes high-strength steel grades above 590 MPa weldable without causing cracks or abnormal hardness, improving both strength and ease of manufacture
4Ease of manufacture
If traditional welding technology is used to manufacture steel wheels, then manufacturing cost is reduced, but material thickness cannot be thinned for weight reduction
Solution Approach 1:
The patent changes the welding technology parameter from traditional MAG arc welding to cold metal transfer (CMT) welding. This enables the use of thinner, high-strength steel materials by producing high-quality welds without cracks or abnormal hardness, achieving weight reduction while maintaining manufacturing cost effectiveness
Solution Approach 2:
The patent uses composite material strategy by combining thin-walled high-strength steel (AHSS) with CMT welding technology. This allows the use of thinner materials for weight reduction while maintaining structural integrity and manufacturing cost efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves lightweight, high-strength steel wheels with significantly enhanced fatigue lifetime, reducing weight by over 30% compared to traditional steel wheels, meeting or exceeding industry standards for radial load and fatigue requirements, while minimizing labor and production costs through automated synchronous welding.
Implementation Method 1
apply low heat input welding, such as the cold metal transfer (CMT) welding
Implementation Method 2
apply low heat input welding, such as the gas tungsten arc welding/tungsten inert gas arc welding (GTAW/TIG)
Implementation Method 3
The welds and the heat-affected zone are narrower; the welded parts have higher welding strength
Data Source
AI summary
The present invention relates to a manufacturing method for advanced high-strength steel (AHSS) wheel, comprising the following steps. Take an AHSS with at least 590 MPa of tensile strength for rolling to circular ring of a rim. Apply low heat input welding, such as the cold metal transfer (CMT) welding or the gas tungsten arc welding/tungsten inert gas arc welding (GTAW/TIG), at the junction of the rim to form a hollow cylindrical rim. Then perform hole expanding and spinning/roll forming operations to the rim. Take another AHSS with at least 980 MPa of tensile strength for pressing and forming a disk. Apply low heat input welding, such as cold metal transfer (CMT) welding, to the rim and the disk to produce a wheel. According to the present invention, the welding quality of products can be improved significantly; the fatigue lifetime of wheels can be enhanced; and wheels are lightweight.