Automobile
Kobelco keeps on providing welding process and welding materials to solve all the problems car manufactures are facing.
Welding Consumables for Automobiles
* Click parts to see the details.
Arm, axle beam
Arm, axle beam
Plate thickness: 2.6 to 3.2mm (arm), 2.6 to 4.0mm (axle)
Features: High strength, fatigue design
Welding length: Fairly long
Welding position: H, F, Downhill
Point: Strength part, extra-low spatter, high speed
Recommended welding procedure
- Power source:
- Pulse or constant potential
- Shielding gas:
- Ar 80% + CO2 20%
- Welding current, speed:
- 250 to 330A - 100 to 150cm/min
- Welding wire:
- FAMILIARC™ SE-A50 (General), FAMILIARC™ MIX-1TS (VD), FAMILIARC™ MIX-50FS (H)
Frame
Frame
Plate thickness: 2.3 to 4.0mm
Features: Many horizontal lap joints
Welding length: quite long
Welding position: Horizontal
Point: Large part, high speed, low spatter
Recommended welding procedure
- Power source:
- Pulse or constant potential
- Shielding gas:
- Ar 80% + CO2 20%
- Welding current, speed:
- 250 to 360A – 100 to 150cm/min
- Welding wire:
- FAMILIARC™ SE-A50, FAMILIARC™ MIX-50FS 1.2mmΦ
Suspension member
Suspension member
Plate thickness: 1.6 to 3.2mm
Features: galvanized steel plate
Welding length: long and short mixed
Welding position: Horizontal, Downhill
Point: Prevention of zinc-induced pits
Recommended welding procedure
- Power source:
- Pulse or constant potential
- Shielding gas:
- Ar 80% + CO2 20%, CO2 100%
- Welding position:
- avoid vertical down welding as far as possible
- Welding current, speed:
- 150 to 250A – 60 to 120cm/min
- Welding wire:
- FAMILIARC™ MIX-1TS, FAMILIARC™ MIX-1Z (Pulse)
FAMILIARC™ SE-50T, FAMILIARC™ MG-1Z (CO2) 1.2mmΦ
Instrument panel reinforcement
Plate thickness: 0.8 to 1.4mm
Features: thin wall
Welding length: short
Welding position: Horizontal, Vertical-down
Point: Prevention measures to burn-through, consistent arc starting
Recommended welding procedure
- Power source:
- Constant potential
- Shielding gas:
- Ar 80-90% + CO2 20-10%, CO2
- Welding current, speed:
- 100 to 180A – 50 to 90cm/min
- Welding wire:
- FAMILIARC™ SE-A50 1.0mmΦ
Torque conveter, Shock absorber
Torque conveter
Plate thickness: 2.6 to 4.0mm
Features: circumferential welding
Welding length: long and short, mixed
Welding position: Horizontal
Point: Horizontal high-speed circumferential welding
Recommended welding procedure
- Power source:
- Pulse or constant potential
- Shielding gas:
- Ar 80% + CO2 20%, CO2
- Welding current, speed:
- 200 to 300A - 100 to 150cm/min
- Welding wire:
- FAMILIARC™ MIX-50FS (Pulse)、FAMILIARC™ SE-A50FS (Pulse)、FAMILIARC™ SE-A50 (CP)
Body Panel
Body Panel
Plate thickness: 0.6 to 0.9mm
Features: Very thin plate
Welding length: very short
Welding position: Horizontal fillet, Vertical down, Horizontal
Point: Prevent burn-through and control root gap of very thin plate
Recommended welding procedure
- Power source:
- Variable AC machine
- Shielding gas:
- Ar 80% + CO2 20%
- Welding current, speed:
- 50 to 120A – 30 to 80cm/min
- Welding torch recommended:
- Push-pull type
- Welding wire:
- FAMILIARC™ MIX-1T 0.6 to 0.9mmΦ
Exhaust manifold, Muffler
Exhaust manifold
Plate thickness: 1.0 to 1.6mm
Features: Stainless steel
Welding length: long and short mixed
Welding Position: Flat
Point: Stainless steel, prevent sensitization, low spatter
Recommended welding procedure
- Power source:
- Pulse
- Shielding gas:
- Ar 98% + O2 2% Ar 80% + CO2 20%
- Welding current, speed:
- 120 to 200A - 30 to 80cm/min
- Welding wire:
- PREMIARC™ MX-A430M, PREMIARC™ MG-S430NbS(Ar-Co2), PREMIARC™ MM-430Nb (Ar100%)
Radiator, Bike frame
Radiator, Bike frame
Plate thickness: 1.0 to 4.0mm
Features: Aluminum alloy
Welding length: long and short, mixed
Welding position: All positon
Point: Aluminum alloy
Recommended welding procedure
- Power source:
- Pulse for aluminum alloys
- Shielding gas:
- Ar 100%
- Welding current, speed:
- 100 to 250A - 50 to 100cm/min
- Welding wire:
- PREMIARC™ A-5356WY, PREMIARC™ A-4043WY 1.2mmΦ
Axle housing
Axle housing
Plate thickness: 2.0 to 10.0mm
Features: Thick plate butt joint
Welding length: Fairly long
Welding Position: Flat
Point: Constant deep penetration
Recommended welding procedure
- Power source:
- Constant potential (thick plate) or pulse
- Shielding gas:
- CO2 100%, Ar 80%＋CO2 20%
- Welding current, speed:
- 200 to 400A - 60 to 100cm/min
- Welding wire:
- FAMILIARC™ MG-50 (CO2) , FAMILIARC™ SE-A50 (Pulse) 1.2, 1.6mmΦ
Introduction of Welding Wire and Process
SE wire, Non-Cu Coated Solid Wire
SE wire and conventional Cu-coated wire
With new wire surface treatment technology, non-copper-coated solid wire offers revolutionary level of wire feedability and unrivaled arc stability. The copper coating process is eliminated from the manufacturing process to minimize the impact on the global environment.
Features
Coating scrap when using copper coated wire
- Kobe Steel's own copper coating free technology
- Low spatter
- Resolves coating scrap trouble
- Excellent wire feedability
Comparison: Spatter Generation
Series of SE Wire for Automobile
| Brand |
Welding Process |
Type of Steel (MPa)
Thickness |
Chemical Composition (Example) |
Mechanical properties (Example) |
| C |
Si |
Mn |
P |
S |
Y.S.
(MPa) |
T.S.
(MPa) |
El.
(%) |
IV
(J) |
|
|
CO2, MAG |
Carbon steel pipe / plate
(1 to 5mm) |
0.07 |
0.49 |
1.02 |
0.008 |
0.016 |
443 |
541 |
28 |
110
(0°C) |
|
|
MAG, Pulsed MAG |
Carbon steel pipe/plate
(1 to 5mm) |
0.06 |
0.62
|
1.27 |
0.010 |
0.015 |
460 |
559 |
28 |
120
(-20°C) |
|
|
MAG, Pulsed MAG |
Carbon steel pipe / plate
(3mm Above) |
0.08 |
0.35 |
1.06 |
0.009 |
0.011 |
460 |
540 |
28 |
150
(-20°C) |
|
|
MAG, Pulsed MAG |
Carbon steel pipe / plate
(2 to 4mm) |
0.04 |
0.70 |
1.20 |
0.010 |
0.060* |
430 |
530 |
31 |
90
(0°C) |
|
|
MAG, Pulsed MAG |
Galvanized steel
Anti-corrosive pipe
(1 to 4mm) |
0.08 |
0.60 |
1.01 |
0.010 |
0.006 |
440 |
540 |
31 |
150
(-20°C) |
Application to Automobile Parts
FAMILIARC™ SE-A50FS: Beautiful Flat and Expansive Beads
- Effect and properties:
- An original design provides beautiful flat and wide beads, reducing welding defects and undercuts.
- At a suitable voltage, slag does not disperse and is less likely to form around craters with lower in quantity, which leads to a reduction in coating defects.
- Bead form is less likely to be affected by weld conditions, making robot teaching easier.
- Stable arc even at high-speed welding prevents the humping phenomenon where beads are constricted. Ideal for pulse MAG welding.
Welding Solution - Galvanaized Steel Sheet
Welding Consumables for Galvanized Steel Sheet
| Process |
Brand |
Coating Weight |
Anti-Porosity
Resistance |
Welding Speed
(cm/min) |
| CO2 |
General |
|
to 60g/m2 |
Fair to Good |
to 80 |
| Special for galvanized steel |
|
to 100g/m2 |
Good |
to 80 |
| PulseMAG |
General |
|
to 45g/m2 |
Fair |
to 100
(Horizontal) |
| Special for galvanized steel |
|
to 60g/m2 |
Good |
FAMILIARC™ MIX-1TS / FAMILIARC™ SE-A1TS
Excellent Anti-Porosity Resistance
| |
① |
② |
③ |
④ |
| Root gap |
0 |
0 |
1 |
0 |
| Welding powersouce |
Constant potential |
Pulse |
| Positon |
Horizontal |
45°
Downhill |
Excellent weldability with root gap
Conventional wire
FAMILIARC™ MIX-1TS
Butt joint (Thickness 3.2 mm, root gap 1.0 mm)
High Speed welding at downhill positon
Welding Wire for Ultra-High Tensile Steel
Feature 1
Applicable for various welding process, such as short circuit, pulse-MAG, and wire feeding control process
* Shielding gas: Ar+20%CO2, sheet: 980TRIP/2.0mmt
Feature 2
Achives sufficient strength welded joint with ultra-high tensile steel, while general welding wire does not achieve
Feature 3
Achieves higher strength joint than spot resistance welding
Arc Spot Welding
Welding current: 210A
Arc time: 0.5 sec
Diameter of spot at lower plate: 4√t
Spot resistance welding
Current: 4KA
Press: 440kgf
Welding time: 15 cycle
Nugget diameter: 4√t
TRUSTARC™ MG-S120T
Diffusible Hydrogen Content (According to JIS Z 3118)
Superior cold crack resistance due to low hydrogen content in weld metal
| Diffusible Hydrogen Content (ml/100g) |
| 1 |
2 |
3 |
Average |
| 1.8 |
1.7 |
1.5 |
1.7 |
Applicable type of steel
780 to 1180MPa class carbon steel
Specification
Welding Wire to Achieve Less Slag
FAMILIARC™ SE-A50FS / MIX-50FS
JIS Z 3312 YGW15, Shielding gas: Ar-CO2 Pulse-MAG welding
How to Achieve “Slag-Less”
Reduce slag of weldind bead with controlling flow of molten pool and bring slag together at the end of welding bead
Smooth Bead Appearance even at Toe of the Bead
Collect slag on the welding bead by balancing the power affacting molten pool
MX-MIG Process FAMILIARC™ MM-1S
Shielding gas: 100%Ar Flux-cored wire for Pulse-MAG
MM-1S enable 100%Ar welding which is unable with solid wire
Minimized Slag Generation
100%Ar welding minimize slag generation with reduction of oxidezed gas
Smooth bead shape even at Toe of the Bead
Corrositon Resistance after Paint Coating
Conventional solid wire / Shielding gas: Ar-CO2
FAMILIARC™ MM-1S & 100%Ar
Welding Wire Specially for Wire Feeding Control Process
FAMILIARC™ MG-1T(F)
JIS Z 3312 YGW12 Shielding gas: CO2 & Ar-CO2
Features
- Reduce wear amount of contact tip by special wire-surface treatment
- Stable of weld bead shape with improved wire feeding
- Suitable for thin steel plates such as parts of automobile parts
Comparison of wear amount of contact tip
Mechanism of Wire Feeding Controll Process
FAMILIARC™ MG-1S(F): Improve Coating / Painting Property by Reduction of Slag Generation
Reduce slag amount on welding bead which harms painting / coating, by collecting slag at the end of welding bead
FAMILIARC™ MG-1S(F) & Ar-10%CO2
Conventional YGW16 & Ar-20%CO2
FAMILIARC™ MG-1Z(F): Improve Porosity-Resistance in Galvalized Steel Sheet Welding
FAMILIARC™ MG-1Z(F)
Conventional Wire
Industries
Page top
stands for FAMILIARC™, 
stands for TRUSTARC™, and 
stands for PREMIARC™.
