What Is an Electrode Forged Grating Welding Machine?

Posted on May 3, 2021

An electrode forged grating welding machine is typically an automatic resistance welding machine like spot welding machines. The electro forged grating welding machines are special welding machines that are designed to fuse the metal parts together in the electro forging process.

What Are Electro-Forged Steel Gratings?

The electro-forged steel gratings are the grating panels that are manufactured utilizing the electro forging process. The electro forging process joins the cross members, the square twisted rods to the primary load-bearing bars, which are mostly made from steel sheets. These electro forging operations are completed in the electrode forged grating welding machine, mostly different types of spot welding machine to permanently fabricate the crossbars and bearings. 

After the metal fabrication, the crossbars are precisely attached to the load members, projecting out of the grating top by approximately 1 mm. The electro-forged steel grating products will typically be produced to a standard length of 600 cm. These grating panels are then slit to the desired dimensions to meet the requirements of the customers.


Introduction to Electrode Forged Grating Welding Machine

The electro forged grating welding machines are special welding machines that are designed to fuse the metal parts together in the electro forging process. An electrode forged grating welding machine is typically an automatic resistance welding machine like spot welding machines. These resistance welding machines, which are also called ERW machines or resistance welders, have great tonnage and employ electrodes that are mostly made from copper, and the copper electrodes will transfer the high density of current and generated heat to the welding point, creating the permanent connection between the cross members and the bearing bars in electro-forged grating production.


● pressure and heat from electrical resistance

Through the thermo-electric process, the contacting point of the metal parts, which is widely known as the weld joint of the electrode forged welding machine will not only be melted by the heat generated due to the electrical resistance, but also be forced by a proper amount of pressure. 


● welding process automation

Most electrode forged grating welding machines that utilize spot welding processes to fuse the metal parts are semi-automated or fully automated, some of them employ robotic technology to upgrade the productional efficiency and accuracy. The weld time and upset time should be critically regulated by the automatic electrode forged grating welding machines to ensure the quality and the strength of the weld.


● high-volume production

Some common types of electric resistance welding ways that employ electrodes to transfer the electric current involve, but not limited to spot welding, seam welding, projection welding, flash welding, and more. These highly automated welding machines are commonly used in high volume production lines or assembly lines of the automotive and aerospace industry, as well as the construction industry and so on.

:: Read More: Electrode Forged Grating Welding Machine Overview


How Electrode Forged Grating Welding Machine Works?

The electric resistance welding process in electrode forged grating welding machines use copper electrodes to convey the stable currents through the interface of the metal bars to join the parts together. The electrodes are mostly made from copper-based alloys because copper features great heat conductivity and relatively low electrical resistance, which is suitable in electrode forged grating welding machines that the heat will melt the materials rather than act on the electrodes themselves. The cooling system of the electrode forged grating welding machine will cool down the conductive tools including the copper electrodes via cool water once the weld cycle is completed.

When the thermal energy is concentrated to the small welding point on the surfaces of the metal parts, the weld joint will be melted. Predetermined amounts of pressure will also form the forces that are applied to the weld joint once the current is removed, forcing and forming the high-quality weld. After the molten joint cools down and solidifies in the electrode forged grating welding machine, the crossbars are accurately joined to the load bearings, ready for further finishing and cutting process.


Different Types of Electrode Forged Grating Welding Machines

Common electrode forged grating welding machines that use the heats generated due to electric resistance involve spot welder, seam welder, flash welder, and projection welder, which can be distinct from the geometry of the weld as well as the way the force is applied to the joint. Following is the introduction of spot welding and projection welding, which are the two typical welding methods used in an electrode forged grating welding machine.


● Spot Welding:

Spot welding is the most common electric resistance welding method that is utilized in the automotive industry for over 100 years. As mentioned, the electrode forged grating spot welding machine transfers the generated heat to melt the "spot". It is greatly suitable for joining sheet metals and high volume applications across the industries like rail industry, aerospace industry, electronics.

When it comes to seam welding, which is one type of spot welding method, it requires a wheel-shaped electrode to transfer the electric current and force toward the "spot". The metal pieces rotate between the wheel-shaped electrodes in the seam welders when the current passes through. 


● Projection Welding:

As for projection welding, the resistance welding method uses projection electrodes that are able to carry greater amounts of current when compared to spot welding. The feature makes projection welding an ideal solution for fusing much thicker materials together. There are two flat electrodes covering the fastener's face, and the projections will absorb the generated heat, creating strong and high-quality welds with utmost aesthetics. The pressure and the contact between the base material and the projections during projection welding help prevent excessive electrode pressure. When compared to other resistance welding ways, projection welding provides ideal heat balance and efficient weld for thicker stocks, making it popular in electrical, automotive, and construction applications.
 

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