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Can Sheet Metal Be Formed With Bends At Weld Joints?

Engineering Asked by ImDumb on June 30, 2021

I understand that a weld, if done properly, is stronger than the base metal. Does this mean that if you have a part that needs to be formed, the bend can be made along the weld? Or is the weld filler more brittle or have some other material property that would prevent this?

As an example, I have the part in the image below. It is to be formed with bend lines at the green dashed lines. Due to manufacturing limitations, I cannot form the entire part at once, so I have to split it, form it and re-weld it. I can split it anywhere along the length of the part. But, out of curiosity, I’m wondering if I can make a vertical cut on one of the green dashed lines (indicating a bend line), form the parts separately, weld them back together, and make the final bend along the weld joint.

The welding process is TIG. The base metal is 1100 Al, which is welded on both sides with 1100 Al filler.

Flat pattern of formed sheet metal

2 Answers

Bend the bits separately then weld them together is one option.

As for welding, bending and forming just take a look on youtube about how some of the old car wings have pieces welded together and are then rolled and stretched to beautiful curves... BUT the experience of some of those guys is phenomenal.

Answered by Solar Mike on June 30, 2021

Depends on base metal, filler metal ( if any ) and weld process and technique. Welds may be weaker or stronger ; more or less ductile than the base metal. No problem with a properly made weld in the right base metal.

Answered by blacksmith37 on June 30, 2021

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