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Tesla All - Aluminum Body Production Process, Advance Knowledge!

- Nov 01, 2018 -

The Model S, developed and manufactured by tesla, the internationally acclaimed us pure electric vehicle manufacturer, contains 250 patents. Its all-aluminum body takes into account both light weight and high strength characteristics. In addition to the body, most of its front and rear suspension materials are also made of aluminum. From a manufacturing point of view, the model is fundamentally different from other cars. Through the real production of video in the following tesla factory, you will know the production process of Model S cars from the selection of raw materials, stamping, welding, painting to final assembly in detail.

Due to the fact that aluminum alloy is sensitive to heat, if the traditional welding process is adopted, there will be the problem of material strength decline. Moreover, due to the easy deformation caused by heat, the size accuracy of the whole aluminum body assembly is not easy to control. So how does the tesla factory overcome the difficulties of the aluminum alloy welding process?

Introduction of CMT cold metal transition technology

In 2005, Austrian welding technology international LTD launched the CMT(Cold metal Transfer) Cold metal transition technology, which for the first time achieved the connection of steel and aluminum in the world. Compared to traditional MIG/MAG welding, the CMT process is really a "" cold transition" ".

Tesla all - aluminum body production process, advance knowledge!

The whole production process of tesla all-aluminum body is absolutely perfect!

CMT melt dripping transition in under the condition of current is almost zero, through the wire back to smoke will drop into the molten pool, heat input, the continuance of a weld heat output time is very short, and thus to weld a cooling process, significantly reduce the welding deformation of sheet, at the same time makes the weld forming good capability of bypass and thus reduces the workpiece assembly clearance requirements and to the accuracy requirement of the jig. CMT weldable thickness is only 0.3mm.

CMT has extremely stable arc. The arc length can be checked and adjusted by the machine. No matter what the surface condition of the workpiece or at what speed you want to weld, the arc is always stable. The welding process is almost free of spatter and burning.

Introduction of DeltaSpot resistance spot welding technology

Volt taspot resistance spot welding process is a new technology developed for aluminum welding. Its innovation lies in the unique electrode belt. The invention of the electrode strip brought unprecedented advantages.

Extremely high process reliability, each resistance welding spot can achieve 100% repeated precision: the mother material and the electrode are protected by the electrode belt, the electrode belt moves between the electrode and the mother material that needs to be joined, so as to realize continuous welding process and ensure constant quality level in multiple shifts.

Each spot USES a new, effective electrode: the electrode tip is protected from wear from the base material and is free from contamination with zinc, aluminum or organic residues. Under such protection, the service life of the electrode is significantly improved. In welding experiments with aluminum plates (AlMg3 alloys), the lifetime of the electrodes is about 30,000.

No spatter on the welding surface: no direct contact between the electrode and the base material ensures no spatter. In particular, when welding aluminum plates, the coating of the electrode strip can optimize the contact with aluminum, avoiding spatter and thus damage parts.

Using the electrode strip, the heat input can be precisely controlled: the connection of three plates (two thick plates and one thin plate) is a difficult problem for traditional spot welding. Solder joints are formed within the thick plate area and are not sufficient to hold the thin plate. And DeltaSpot's electrode strip controls the depth of the solder spot with its extra heat input. As a result, the low heat in the sheet range can be compensated by the high resistance of the electrode strip. The solder spot penetrates sufficiently into the sheet in this manner. At the same time, the weld shape is more symmetrical and the weld volume within the thin plate is larger.

DeltaSpot not only performs well in aluminum welding, but also has incomparable advantages in different thickness/material welding, such as high-standard welding spot appearance and high-strength steel material welding on surface coating. The welding base material of DeltaSpot includes: high strength steel, surface coating material, aluminum, stainless steel, titanium, magnesium, composite material, etc.