Abstract: With the deepening of the process of vehicle lightweight, the application of aluminum panels is becoming increasingly widespread. Stamping cracking is the main process challenge faced by aluminum materials in vehicle applications, and the high scrap rate caused by stamping cracking seriously affects production efficiency and cost control. This study developed an integrated method for repairing and quality verification of cracked aluminum panels based on a systematic analysis of cracking issues and the material properties of aluminum panels and established the repair process with melt inert-gas (MIG) welding as the core method. Mechanical tests demonstrated that samples after MIG welding exhibited significant improvements in tensile strength, yield strength, and maximum breaking load. Results from production applications showed that this method not only substantially enhanced the mechanical properties of repaired cracks but also reduced the overall part scrap rate to approximately 5%. This research provides an effective engineering solution for the repair of aluminum plate stamping cracking, offers a basis for repair quality evaluation through comparative qualitative testing, filling the industry gap, and has significant promotion and application value.

Key words: lightweight body; aluminum panel cracking; melt-insert-gas welding; mechanical performance

摘要： 伴随车身轻量化进程的深入，铝板应用日益广泛。冲压开裂是铝板在车身应用中面临的 主要工艺挑战，由冲压开裂导致的报废率居高不下，严重影响生产效率与成本控制。研究基 于对开裂问题的系统梳理与铝板材料特性分析，构建了一套集返修与质量验证于一体的方法， 并确立以熔化极惰性气体保护（MIG）焊接作为核心方法的返修工艺。机械性能测试表明， 经 MIG 焊接后的样片，其抗拉强度、屈服强度和断裂载荷均显著提升。应用结果显示，该方 法不仅大幅提高返修后裂缝的力学性能，还将整体零件报废率降至约 5%。该研究成果为铝板 冲压开裂返修提供了有效的工程解决方案，通过定性测试对比分析为返修质量评价提供依据， 填补了行业空白，具备显著的推广应用价值。

关键词: 车身轻量化；铝板开裂；熔化极惰性气体保护焊接；力学性能