ZAO BECEMA, located in Krasnogorsk, near Moscow, manufactures tank trucks for heavy or light mineral oil transportation. ZAO BECEMA invested in a new factory lay-out, new machines for aluminium fabrication, and tools and clothing for workers, only for use on aluminium. The Russian Samara aluminium works was able to supply width AlMg5 plates with sufficient strength and ductility. A tank consists of a long cylindrical body, closed on both sides by caps. Internally the vessel is divided into several sections by walls with the same form as the caps, according to the contractor's requirements. The automatic plasma welder fabricates plates with a width up to 6 m, which are rolled to a cylinder. To close the cylinder, a final double-sided longitudinal run is performed by pulse MIG welding. All caps, separation walls and deflector plates are connected to the tank with fillet welds made by pulse MIG. If the tank length exceeds 6 m, cylinders are joined with a circumferential weld made in the same way as the longitudinal welds - pulse MIG on ceramic backing strip. The semi-automatic MIG welding of plate sections with a size of 6000 mm x 6300 mm x 6 mm from separate sheet plates proved not to be feasible because of strong distortion and many defects. This problem was effectively solved with the ESAB FD60HP plate seamer and PT-8 plasma torch. This equipment welds carbon and stainless steel without weld pool support and shielding gas while, for aluminium plate, a copper backing bar is normally used. The welding parameter range for a stable process - giving full penetration welds and no weld pool collapse - was too narrow for practical use. The tip-wear of the tungsten electrode, resulting in a less focused arc, already caused lack of fusion within a weld length of 6 m. OAO Kriogenmash, a Russian company with great experience in aluminium vessel fabrication, provided the solution. They recommended a special stainless backing bar with a very specific root shape, which promotes a forced root formation. This increased the process stability sufficiently and widened the parameter range. It made the welding operation less sensitive to heat input, with reduced risk of burning through or the entrapment of oxides.
Manufacture of mobile gasoline tanks in AlMg5 aluminium alloy at ZAO BECEMA, Russia. ESAB assists in converion from steel to aluminium
Svetsaren, English Edition ; 63 Heft 1 ; 47-50
2008
4 Seiten, 5 Bilder, 3 Tabellen
Article (Journal)
English
Herstellung , Tankfahrzeugbehälter , Aluminiumlegierung , Druckfestigkeit , Duktilität , Einbrand (Schweißnaht) , Wanddicke , Metall-Inertgasschweißen , Impulstechnik , Verwerfung (Verformung) , Plasmabrenner , Schweißbad , Schutzgas , Schweißparameter , Oxid , mechanische Eigenschaft , Phototechnik , Einbrandfehler , Elektrodenwerkstoff
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