Feasibility of Welding Combat Vehicles by the Resistance Flash Welding Process

摘要

Conventional and non-conventional methods for accomplishing each step in the flash welding process were reviewed and certain further studies of them were recommended for optimization of the process. Four combat vehicles were redesigned for flash welding and five machines recommended for mass production of them. These have platen widths from 31 to 202 inches and depths from 22 to 241 inches, produce upset forces from .9 to 13 million pounds, and have electrical demands from 5 to 39 megavolt-amperes. Locations of twenty-three power systems capable of meeting the maximum demand of one machine at selected points were shown and methods of reducing demand to permit further freedom of location were presented. Trial welds in four aluminum armor alloys (2219-T87, 5083-H113, 6061-T6, and 7039-T6) were reviewed. Study of motion records, examination of one weld, and strength tests of all showed that these flash welds exceed fusion welds in tensile strength and that production flash welds should exceed ninety percent joint efficiency. (Author)