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Truck Axle Seat Spring Base Welding - Using Artsen PM500F MIG/MAG Welder

I. Truck Axles: Their Characteristics and Advantages

Within the triad of truck power cores—engine, gearbox, and axle—the axle assumes a pivotal role in the transmission of power, wielding profound influence over the vehicle's stability and dynamics.

Bridging the gap between suspension and chassis while accommodating truck wheels at both ends, the axle functions as a pivotal structure transmitting directional forces and torque between the chassis and wheels. Axles come in two principal structures: integral and detachable. The integral type, resembling a colossal lever, is supported by the suspension system at both ends, often in tandem with non-independent suspensions. In contrast, detachable axles resemble twin umbrellas, individually supported by the suspension system, commonly utilized with independent suspensions.

Diverse in driving mechanisms, axles branch into four categories: steering, driving, steering-drive, and support axles. In the majority of trucks employing front-engine rear-wheel drive (FR), the front axle handles steering duties while the rear drives. Conversely, in front-engine front-wheel drive (FF) trucks, the front axle manages both steering and propulsion while the rear supports.

Truck Axle

P1 Truck Axle

II. Clients Engaging Axle Welding Services

Established in 1997, the Guangdong Fuwa Machinery Group stands as a global pioneer in commercial vehicle (trucks, trailers, and engineering vehicles) axle and chassis component manufacturing. Operating worldwide under four prominent brands—FUWA (in China and Asia), VALX (in Europe), AXN (in North America), and K-Hitch (in Australia)—the group's vast empire spans over 2.5 million square meters, comprising 11 manufacturing plants, 2 logistics ports, 4 overseas companies, and a Sino-German joint venture.

Pioneering a philosophy centered around humanity, quality, autonomous innovation, and continuous enhancement, the group's subsidiaries boast certifications such as ISO9001:2015, IATF16949, and ISO14001:2015, positioning them as national high-tech enterprises.

The group's prime offerings encompass semi-trailer axles, truck axles, passenger vehicle axles, engineering axles, refrigerated containers, support legs, suspension systems, saddles, traction pins, friction plates, control arms, and air chambers. Most boast proprietary technology, meeting quality standards in the US, EU, and Australia, and exported to over 80 countries and regions, establishing the group as a revered and trusted manufacturer of specialized road vehicle components. Notably, in 2017, the group's axle production and sales exceeded 1 million units, setting new industry benchmarks.

Fuwa Factory
P2 Fuwa Factory

III. Challenges Encountered at Axle Welding Sites

Comprising parts such as the semi-axle casing, fixed plate, rear cover, flange, and semi-shaft sleeve, among others, the axle seat spring base plate, symmetrically positioned, serves to secure steel plate springs through 8 angular weld seams. Constructed typically with Q345 for the casing and Q235 for the seat plate, both with a thickness of 12mm, the welding involves angular connections with an 8mm seam height. Client specifications necessitate a fusion depth exceeding 1mm, a Rockwell hardness for the seam below 78HB, and below 83HB in the heat-affected zone. Previously employing thyristor welding machines at 260A direct current resulted in extensive spattering, large granular spatter on the surface, demanding laborious post-weld grinding.

IV. Artsen PM500F Welding Machine: Features and Advantages

Catering to client needs, the recommended solution is the Artsen PM500F welding machine from Megmeet, employing carbon steel pulse technology. The Artsen PM500F welder stands as a fully digital high-frequency intelligent inverter welder, facilitating direct current pulse welding across all positions for carbon steel. This welding marvel presents numerous advantages to resolve client concerns:

1)Optimized Pulse Technology: Concentrating arc energy, deepening fusion depth, reducing heat input, and minimizing spatter.

2)Diverse Pulse Data Storage: Storing multiple pulse data, ensuring a wide application range and delivering superior welding results.

3)Precision Wire Feeding Mechanism: Leveraging high-performance digital motors, encoders for feedback, four-wheel wire feeding, and accurate feeding structures ensuring stable wire delivery for impeccable welding.

V. Comparative Analysis of Axle Welding Effects

Compared the welding result of the Artsen PM500F welding machine with that of the thyristor direct current welding machine, Artsen PM500F significantly reduced labor intensity for grinding, decreasing spatter by over 80%, and elevating welding efficiency by 23%. Seam qualification rates surged to over 99%. The hardness of both seams and the heat-affected zone aligned seamlessly with specified requirements.

VI. Application of Artsen PM500F Welder

Artsen PM500F Welder Application
P3 Artsen PM500F Welder Application