In new energy vehicle (NEV) manufacturing, aluminum welding is crucial. It’s used for battery casings, body frames and more. Stable wire feeding is a must—minor fluctuations ruin weld quality. Below is a practical optimization case from an NEV battery casing laser welding line. It focuses on EV aluminum welding wire feed fixes.
Original Production Line Issues
The production line used ER5356 wire to weld aluminum end plates of battery casings. Wire feeding issues caused an 8.2% defect rate, mainly porosity and incomplete fusion. Daily downtime for debugging even exceeded 40 minutes. Core problems included: ordinary spring wire guides with high friction (causing jams), unreasonable retraction parameters (twisting wires), and substandard wire magnesium content (insufficient hardness).
Optimization Measures (Aligned with Standards/Technical Data)
1. Wire Guide Replacement
We followed Aluminum and Aluminum Alloy Welding Technical Regulations (HG/T 20222-2017). It specifies standards for aluminum welding wire feeding channels. We replaced ordinary spring wire guides with Teflon ones. We also shortened the guide to 4.5 meters to avoid bending.
2. Wire Retraction Parameter Adjustment
We referred to the industry document Ultimate Solutions for Poor Wire Feeding in Aluminum Laser Welding. We adjusted wire retraction from 8mm to 2.5mm. Wire replenishment was set to 0.8mm. This effectively prevented wire twisting and jamming.
3. Wire Specification Upgrade
We replaced non-standard low-magnesium wire with standard ER5356. Many cheap non-standard options on the market claim to be ER5356 but have magnesium below 3%. This shortage makes wires overly soft, causing feeding jams and brittle welds. Our standard ER5356 meets GB/T 10858-2023, with 4.5-5.5% magnesium ensuring stable feeding—find it at SWT ER5356 aluminum welding wire.
Optimization Effects
Optimization yielded impressive results. Aluminum welding wire jamming dropped by 92%. Weld defects fell to just 1.1%. Daily downtime shortened to 6 minutes. Single-line capacity even rose by about 12%. These EV aluminum welding wire feed solutions work for similar production lines.