Abstract: Due to the easy oxidation of aluminum profiles in the air and the melting point of the oxide layer is very high, the weldability defects of aluminum profiles lead to many difficult problems in the arc welding process of thick plate aluminum profiles, such as bubbles, splashes and arc failures. This paper introduces the arc welding problem encounter in the new energy vehicles field of aluminum battery shell arc welding process, comprehensive analysis of the factors that contribute to the failure of arc welding of aluminium profiles, such as grounding, wire feed system, welding parameters, etc., and the process of solving the problem are summarised.The optimization measures proposed in this paper have a good guiding significance to solve the problem of aluminum arc welding in aluminum arc welding process.

Key words: New energy vehicles; Aluminum shell; Aluminum arc welding; Battery shell; Arc start failure

摘要： 由于铝型材在空气中易氧化，且氧化层熔点非常高，铝型材的焊接性缺陷导致厚板铝 型材弧焊工艺会遇到很多的棘手问题，例如气泡、飞溅以及起弧失效等。文章介绍了在新能 源汽车领域铝电池壳体弧焊工艺中遇到的起弧问题，全面分析总结了铝型材弧焊起弧失效的 因素，如接地、送丝系统、焊接参数等以及问题解决过程。文章提出的针对性优化措施对解 决铝弧焊工艺中的铝型材弧焊问题解决有较好的指导意义。

关键词: 新能源汽车；铝壳体；铝弧焊；电池壳；起弧失效