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Production welding aluminum parts with flash-butt or resistance-butt

Production welding aluminum parts with flash-butt or resistance-butt

Production welding aluminum parts with flash-butt or resistance-butt

(OP)
My company is designing a production line for a new product.  Two of the parts are aluminum near-mirror images of each other, and were to be assembled with adhesive.  The customer change-ordered the fabrication to be welded instead.  

Sketches of one of the two parts is shown below.  The bottom-left section drawing is hatched to show the planar surface that needs to mate and be welded to the mirror-part.  The total surface area to be welded is 121 mm^2  [0.188 inch^2].

I'm thinking about Flash-Butt Welding or Resistance-Butt Welding since both can produce a gas-tight continuous seam, minimal part distortion, and automate well.  

The aluminum spec'ed is 6061-T6.  I'm aware that this is not the best aluminum for welding, and would like suggestions for a better aluminum that still has good anti-corrosion and weathering properties.

The advantage of the Flash-Butt process for aluminum seems to be that it flashes the aluminum oxide in the weld area without pre-cleaning the part.  Am I missing something, or is the Flash-Butt process a good match for this task?

Thanks very much for looking at my problem!
Dave


 

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