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The cross wire projection welding of wires (Al 5182, =4 mm) performed using the conventional (i.e. pneumatic) electrode force system was subjected to thorough numerical analysis. Calculations were performed until one of adopted boundary conditions, i.e. maximum welding time, maximum penetration of wires, the occurrence of expulsion or the exceeding of the temperature limit in the contact between the electrode and the welded material was obtained. It was observed that the ring weld was formed within the entire range of welding parameters. The process of welding was subjected to optimisation through the application of a new electromechanical electrode force system and the use of a special hybrid algorithm of electrode force and/or displacement control. Comparative numerical calculations were performed (using SORPAS software) for both electrode force systems. Technological welding tests were performed using inverter welding machines (1 kHz) provided with various electrode force systems. The research also involved the performance of metallographic and strength (peeling) tests as well as measurements of welding process characteristic parameters (welding current and voltage). The welding process optimisation involving the use of the electromechanical force system and the application of the hybrid algorithm of force control resulted in i) more favourable space distribution of welding power, ii) energy concentration in the central zone of the weld, iii) favourable (desired) melting of the material within the entire weld transcrystallisation zone and iv) obtainment of a full weld nugget.

Cross-Wire Projection Welding of Aluminium Alloys in Relation to Pneumatic and Electromechanical Electrode Force Systems