关键词: 铝合金油箱；焊缝分析；放油塞；材料试验；振动耐久试验；可靠性分析

Abstract: The aluminum alloy fuel tank used by a heavy-duty truck has been exposed to the problems of cracking at the drain plug boss and leaking oil at the weld of the drain plug in the market application process. The paper analyzes and verifies the structure of the oil drain plug and finds that the reason is mainly caused by the unreasonable structure and layout of the seal. After that, through analysis and verification of welding defects, vibration endurance test, material comparison test, sealing reliability and process improvement, the existing structure is optimized to solve the oil leakage problem of the fuel tank, improve the durability of the fuel tank, reduce market loss, and provide a reference for the subsequent research on the improvement of the fuel tank.

Key words: Aluminum alloy oil tank; Weld analysis; Drain plug; Material test; Vibration endurance test; Reliability analysis