Automatic Welding Machine Guide

Welding is arguably the most complicated and often least understood manufacturing process. Manual welding is also the safest process for a variety of assemblies. Many fitters, however, introduce automated welding systems to improve efficiency, productivity, and profitability. Welding automation can be divided into two specific categories: semi-automatic and fully automatic. The operator manually loads the pieces into the welding gun during semi-automatic welding. The welding controller then maintains the welding phase, the torch movement, and the part immobility according to the parameters set. After welding, the user removes the finished assembly and the process begins again.

Types of Automatic Welding Machines

Automatic welding machines can be grouped into CNC controlled automatic welders, which use welding automation, and robot welding, which is done by robots or robotic arms. Automatic welding is used to constantly repeat welding in a manufacturing line. Robot welding is an advanced version of automatic welding that uses robot technology to automatically allow a higher level of welding and achieve more complex welding results, while further increasing productivity. To take advantage of processing time improvements from automatic or robotic welding, inspection processes have been simplified through the use of laser beam-based displacement sensors.


Advantages of Automatic Welding Machines

Automated welding systems offer four main advantages: increased productivity, better welding quality, less waste, and less variable labor costs. Two factors contribute to the consistency of the weld: integrity of the weld and repeatability. Automated welding systems maintain the integrity of the welding with electronic welding process controls. The combination of mechanized torch and component movements with electronic welding parameters retrieve results in higher-quality welding than can be performed manually. This ensures an immediate quality management process. Moreover, since welding is only performed once, defects are readily visible and detectable. People tend to smooth out a burnout mistake, hide no penetration, or even a bad weld. In some cases, leak test and vision systems may be incorporated into fully automated systems to provide additional quality control.

Repeatability is a function of the consistency of the welding process controller and machine motion controller. Mechanized welding provides repeatable input parameters for reproducible performance. Assuming the controller is working properly, the question arises: can the system mechanisms place the parts or torches within the defined welding tolerances? The response to this question will prove the consistency of the device purchased.


Automatic Welding Machine Types

Automated MIG Welding Machines

MIG welding is a type of gas arc welding (GMAW) that uses a continuous wire during the welding process. This wire acts as a filler material, helping to connect two welded metal objects. MIG bare wire welding can be used to join thin pieces of metal together. MIG welding with a flux-cored can be used outdoors as it does not require a flow meter or gas supply.


Automatic TIG Welding Machines

TIG welding is another name for gas tungsten arc welding. It uses non-fusible welding wires or tungsten electrodes. Current flows into the two materials to be welded so that they can be heated and fused. TIG welding may or may not use filler materials. TIG welding is extremely flexible, but it is also one of the most difficult welding techniques to perform, especially for non-automatic welders. Automated TIG welding solutions are now easily available. The machine feeds the bar automatically and holds the TIG torch. This torch produces heat and arc used to weld most conventional metals, including aluminum, steel, nickel alloys, copper alloys, cobalt, and titanium.


Automatic Plasma Arc Welding Machines

Plasma arc welding is a precision technique and is commonly used in aerospace applications where the metal thickness is very thin. An example of such an application would be an engine blade or an air seal. Plasma arc welding is somewhat similar in technique to TIG welding, but the electrode is recessed and the ionizing gasses within the arc are used to produce heat.


Automatic electron beam and laser and gas welding machines

Electron beam welding and laser welding are extremely accurate high-energy welding techniques. Gas welding is seldom used anymore and has been increasingly replaced by TIG welding. Gas welding kits require oxygen and acetylene and are highly portable. Often they're also used to re-weld car exhaust fragments.

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