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Truck Axle (head & housing) Welding - Using Artsen PM500F MIG/MAG Welder

I. Truck Axles: Powerhouses of Stability

The engine, gearbox, and truck axle constitute the triumvirate of a truck's power core. Among these, the truck axle plays a pivotal role in the transmission of power, profoundly influencing the vehicle's stability and propulsion.

Connecting the suspension and the chassis while supporting truck wheels, the axle operates as a bridge conveying forces and torque between the chassis and the wheels. Two primary axle designs exist: integral and detachable. The integral axle, akin to a colossal lever, is supported by the suspension system at both ends and is commonly paired with non-independent suspensions. In contrast, the detachable axle resembles two umbrellas flanking the vehicle, each supported individually by the suspension system, often paired with independent suspensions.

Categorically, axles differ based on their driving mechanisms: steering, driving, steering-drive, and support axles. The majority of trucks employ front-engine rear-wheel drive (FR), designating the front axle for steering and the rear for driving. Conversely, front-engine front-wheel drive (FF) trucks position the front axle for steering and propulsion, relegating the rear axle to support.

P1 Appearance of Axle

P1 Appearance of Axle

II. Clientele Utilizing Axle Welding Services

Established in 1997, the Guangdong Fuwa Machinery Group stands as a global leader in manufacturing commercial vehicles (trucks, trailers, and engineering vehicles) axles, and chassis components. Operating under four major brands—FUWA (in China and Asia), VALX (in Europe), AXN (in North America), and K-Hitch (in Australia)—the group spans over 2.5 million square meters, encompassing 11 manufacturing plants, 2 logistics ports, 4 overseas companies, and a Sino-German joint venture.

Adhering to a philosophy centered on people, quality, innovation, and continuous improvement, the group's subsidiaries have obtained certifications such as ISO9001:2015, IATF16949, and ISO14001:2015, marking them as national high-tech enterprises.

Their product range includes 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 of which possess proprietary technology. Compliant with standards in the US, EU, and Australia, and exported to over 80 countries and regions, the group has earned acclaim as a respected manufacturer of specialized road vehicle components. Notably, in 2017, their axle production and sales surpassed 1 million units, setting an industry record.

 Fuwa Factory
P2 Fuwa Factory

III. Axle Welding Requirements

Primarily composed of semi-axle casings, fixed plates, rear covers, flanges, and half-shaft sleeves, axle welding entails two circular seams between the half-shaft sleeves and the axle casing. These seams secure the relative positions of the left and right wheels, maintaining a stable center, and supporting the vehicle frame and its components. Typically, the axle casing material is Q345, while the shaft head material is 40Mn, a medium-carbon quenched and tempered steel, exhibiting poor welding properties with a thickness of 7-15mm. Employing a narrow gap bevel for docking, the bevel's form is illustrated in Figure 1, featuring a β angle of 3 degrees, an R radius of 8mm, and a blunt edge of 2mm at the B1 root.

Client specifications demand strict control over the width of the heat-affected zone while enhancing grain refinement and toughness. The weld should be devoid of defects and spatters, ensuring overall weld quality, and meeting design requirements for strength and fatigue life. The welding machine's communication with specialized equipment is simple and reliable, boasting high power reliability, suitable for prolonged operations, and ensuring consistent batch production of high-quality welds.

axle breakdown drawing
P3 Axle Breakdown Drawing

Schematic diagram of weld groove

  P4 Schematic diagram of weld groove

IV. Advantages and Features of Artsen PM500F Welding Machine

Addressing client needs, the recommendation is the Artsen PM500F welding machine from Megmeet, integrated into an automatic double-circular seam welding equipment for axle heads. Employing carbon steel pulse technology, Artsen PM500F represents a fully digital high-frequency intelligent inverter welder, capable of direct current and pulse welding of carbon steel. The machine offers several advantages to resolve client concerns:

1)Precision through Digital Control: Enables precise droplet-by-droplet welding, ensuring stable and spatter-free welding.

2)Optimized Pulse Technology: Concentrates arc energy, deepening fusion and accelerating welding speed, effectively reducing overall heat input and controlling the width of the heat-affected zone.

3)Storage of Various Pulse Parameters: Wide applicability for achieving superior welding outcomes.

4)Enhanced Wire Feeding Stability: Utilizes high-performance digital motors, four-wheel wire feeding, and precise feeding mechanisms, ensuring stable wire feeding for excellent welding results.

5)Multiple Communication Modes: Equipped with analog, digital, and other communication interfaces, facilitating straightforward communication with specialized equipment and robots.

6)High Power Reliability: Ensures consistent parameters, guaranteeing stable and reliable welding of large batches by specialized machines.

Welding Workpieces
P5 Welding Workpieces

Welding Workpieces
P6 Welding Workpieces

V. Comparative Effectiveness of Axle Welding

Fuwa, employing the Magmatech Artsen PM500F alongside specialized equipment, conducts simultaneous welding with two welding guns.

  • 1) The specialized equipment, controlled by PLC, enables automatic oscillation, lifting, and tracking of the weld seam, boosting overall efficiency by 50%.

  • 2) The welding machine operates stably for extended periods, ensuring high weld consistency, and attaining a 99% product qualification rate.

  • 3) With excellent fusion and sufficient depth, the weld speed is swift, minimizing spatter and eliminating the need for grinding.

  • 4) Notably, the heat input is reduced by 17%, meeting the fatigue performance requirements set by the clientele.

Applications of Artsen PM500F Welding Machine

Double Annular Seam Welding

P7 Double Annular Seam Welding