Need feedback on my jig design for welding aluminum sheet metal – flatness + dimensional control is key 1

[ShanXXX]

Working on a jig to weld an aluminum sheet metal part. Goal is to keep flatness tight and hold final dimensions during and after weld. I’ve roughed up a first draft of the fixture – but wanted to throw it out to the hive mind here to see how others would approach it. Would love to hear how you'd jig this up.

Here’s what’s up:

The part is aluminum, not too thick, mostly flat geometry.

Tolerance on flatness is critical post-weld.

I can split the part however – no restrictions on where seams go.

Jig needs to handle minor distortion from weld heat – or at least contain it.


Attached are:

Model of the part

First jig concept I built



If you were me, how would you jig this up? Any pro tips on controlling distortion with aluminum specifically? Appreciate all input – trying to make this tight.

 

[mfgenggear]

Pdf file would be good

 

[mfgenggear]

Is the green portion is part of the assy?

 

[3DDave]

Welding aluminum and flatness do not go together.

 

[ShanXXX]

Is the green portion is part of the assy?

Yes.green is the part

 

[mfgenggear]

Pdf file please. So we can view on phone

 

[ShanXXX]

Pdf file please. So we can view on phone

Attched 3d pdf for view.

 

[mfgenggear]

OP
please advise which area gets welded if possible.
a welding fixture is mostly for tack welding in place. the procedure is 75% of maintaining distortion free.
the best type welding from my past history was tig or electron beam welding.
preheating aluminum is a must, the clean and prep is a must,
it can be done. I had great results in the past with more complex geometry.
the welding fixture needs access to allow the welder to tic weld in place and to do intermittent welding. the welding
needs to be divide evenly and not concentrated in one area.
the fixture is very well design except for access. it should help draw the excessive heat.
a weld schedule would be very helpfull to the the fitter and welder. both are very important.
I forgotten much, and the little details are important. size of the filler rod, type material, the voltage setting, DC amperage.
distance and length of tacks minimal amperage to prevent excessive heat, # of passes.
automatic tig welders were great because the inches per minute and distance maintained from the weld are a was consistent.
electron beam welding all most zero excessive heat and its in a vacuum. same consistent welds.
in oder to give more advice I need to view the welded areas with a weld note.
some aluminum does not weld well, pull the data sheets on the material , and reseach weldability and recommendations.
remember said preheat is important and the 25% argon and 75% helium jumps in my head. but seek
more advice from a weld engineer, they are thy specialist on this.

 

[ShanXXX]

OP
please advise which area gets welded if possible.
a welding fixture is mostly for tack welding in place. the procedure is 75% of maintaining distortion free.
the best type welding from my past history was tig or electron beam welding.
preheating aluminum is a must, the clean and prep is a must,
it can be done. I had great results in the past with more complex geometry.
the welding fixture needs access to allow the welder to tic weld in place and to do intermittent welding. the welding
needs to be divide evenly and not concentrated in one area.
the fixture is very well design except for access. it should help draw the excessive heat.
a weld schedule would be very helpfull to the the fitter and welder. both are very important.
I forgotten much, and the little details are important. size of the filler rod, type material, the voltage setting, DC amperage.
distance and length of tacks minimal amperage to prevent excessive heat, # of passes.
automatic tig welders were great because the inches per minute and distance maintained from the weld are a was consistent.
electron beam welding all most zero excessive heat and its in a vacuum. same consistent welds.
in oder to give more advice I need to view the welded areas with a weld note.
some aluminum does not weld well, pull the data sheets on the material , and reseach weldability and recommendations.
remember said preheat is important and the 25% argon and 75% helium jumps in my head. but seek
more advice from a weld engineer, they are thy specialist on this.

I have attached some pictures welding area of the part. Drawing didnt call for any welding as this part can be manufatured in best known method as long as fi al dimensions matches requirement. Alu 5052 material was used

 

[mfgenggear]

OP
This material readily weldable
But that's a lot of welding.
All those weld areas require access for tac welding. The fixture will need redesign.
May need two or more fixtures to be dine in stages. Tac up the complete assy. Then finish weld.

Copy of the material data sheet

https://www.southernmfg.com/modules/products/files/Aluminum205052.pdf