Welding Process for Custom Non-standard Components: From Design to Delivery

The welding and fabrication of non-standard structural components are characterized by complex structures, small batch sizes, and frequent variations, which place higher demands on the welding enterprise’s response speed, process capability, and quality control.

Technical Drawing Evaluation

Weldability Analysis: Are the weld seam positions reasonable? Can the welding torch access the joints? Are there assembly interferences?

Extraction of Dimensions and Tolerances: Confirm datum surfaces, mating holes, and tolerance reference points.

Preliminary Welding Sequence and Process Planning: Evaluate whether welding jigs/fixtures are needed, and whether post-weld deformation risks exist.

Technical Communication with Client: Communicate promptly regarding unreasonable structures or unclear requirements to avoid rework at later stages.

Material Preparation and Preprocessing

Material Inspection: Verify material grade, batch number, and mechanical properties to ensure compliance with drawing requirements.

Cutting and Blanking: Choose laser/plasma/saw cutting methods based on part size and precision requirements.

Beveling and Numbering: Pre-bevel complex structures and assign numbers to facilitate on-site positioning and assembly.

Surface Cleaning: Remove oil and rust to improve weld joint quality and prevent porosity.

Especially for aluminum alloy and stainless steel structures, surface pretreatment is critical and directly affects the strength and appearance of the welds.

Welding Process Implementation

Welding is the core stage of the entire process, and its quality directly impacts structural precision and subsequent assembly. We apply the following control measures:

Preparation of Welding Procedure Specification (WPS): Includes welding sequence, current and voltage parameters, filler material type, preheat/interpass temperature, etc.

Welding Fixtures for Positioning: Improve assembly accuracy and prevent deformation during welding.

Segmented and Symmetrical Welding: Especially applicable to large-size or thin plate structures to effectively control distortion.

Post-Weld Processing and Quality Inspection

After welding, the workpieces undergo a series of post-processing and inspection steps to ensure they meet client delivery standards:

Weld Appearance Inspection: Ensure no undercut, porosity, or cracks.

Dimensional Re-Inspection: Focus on rechecking datum surfaces, threaded holes, and mating holes.

Weld Grinding: Perform slag removal, smoothing, and treatment of weld spatter as required by appearance specifications.

Subsequent Machining (if necessary): Post-weld machining to ensure structural alignment and dimensional accuracy.

Surface Treatment and Packaging for Delivery

Provide corresponding coating or anti-corrosion treatments according to client requirements. Finally, package according to export or industrial protection standards, along with inspection reports, photo documentation, and delivery checklist.