Resistance Welding Machine Guide
A Brief Look to Resistance Welding
Resistance welding is a technique of joining metals or other thermoplastic materials by pressure and the passing current.
When joining two materials using resistance welding, the technician needs to allow the current pass through the metal area which is to be joined for a length of time.
This technique is cost effective because it allows the two materials joining together without adding any other elements. Thus, the cost of buying adhesive elements would be saved.
There are four ways of resistance welding. Each of them has different function and application.
● Resistance Spot Welding
● Spot Welding and Seam Welding
● Projection Welding
● Flash Welding
● Upset Welding
Introduction of Resistance Welding Machine
A resistance welding machine is a kind of industrial equipment that used to join metals or other thermoplastic materials by heats.
When the resistance welding machine works, it would heat the contact surface of the two elements ready to be joined by electronic flow. The heating process would be continued until the two contact surfaces milt. Thus, they would produce stickiness that can be jointed together.
In the resistance welding machine, there contains the welding power supply to control welding current, a weld head to add pressure on the material, and an electrode to provide welding current and pressurization force to the part under welding.
The electrode is typically made of copper-based alloys because of the excellent conductive properties. Usually, they would be cooled down by the water flowing through cavities inside the electrode and the other conductive tooling of the resistance welding machine.
Types of Resistance Welding Machine
Categories of resistance welding machine can be various. They can be classified by welding techniques, ways of adding pressure to the electrode, and types of current.
Below is the category of welding techniques:
● Spot Welding Machine
Spot welding is a technique of electric resistance welding used to weld various sheet metals together. When working by this technique, the current would be passed through joining metal surface points, then joined together with the heat made by current.
● Seam Welding Machine
Seam welding is a technique of electric resistance welding used to join materials together by using the current pass through the metals and press them together with machine tools. Thus, the materials would be joined together.
● Projection Welding Machine
Project welding is a technique that using current to join materials together. Materials ready to be joined together would be designed as one flat and the other arched.
When using this technique, the current would be passed through these two materials. When the current passes through the arch, it would crush down because of the heat the current produced. Them, the two materials would be joined together.
● Butt Welding Machine
Butt welding machine is also called but welder. It is a resistant welding machine using the technique of linking two materials with heat, pressure, or both. This is a commonly used technique around welding factories since it is economical.
Dividing by ways of adding pressure to the electrode, they can be categorized as these classifications below:
● Leveraged Welding Machine
● Electric Cam Welding Machine
● Pneumatic Welding Machine
● Hydraulic Welding Machine
● Combined Welding Machine
And distinguishing by the current type:
● Single-phase AC Welding Machine
This is the most commonly used welding machine. Since it uses the single-phases alternate current (AC), it can meet the need of welding steels with low carbon containing.
● Intermediate Frequency Welding Machine
This is the machine that works with the most innovative welding technique. The main technical point of the intermediate frequency welding machine is the proficiency of its welding controller and transformer.
With the intermediate frequency welding machine, the progressing works of aluminum, aluminum alloy, galvanized sheet, and other special materials can be done well in high qualities.
The current would be adjusted by this machine’s transformer and then applies to the whole machine with direct current (DC) by the electrode. It can largely increase the power factor to the maximum and ensure the quality of welding work. Moreover, comparing with single-phase AC welding machine, this welding machine can save 30% energy.
● Three Phase Secondary Stage Rectifying Welding Machine
This kind of welding machine is used to do point welding. Its main features are these two: being able to weld with high power and containing low damage to the electrical net. Thus, it can longer the lifespan of welding machine in some level.
Now, it is commonly used in flash butt welding and seam welding.
● AC Frequency Conversion Welding System
The AC frequency conversion welding system is mainly used in seam welding. Its main feature is that it can keep the balance of the three phases. Moreover, this kind of resistance welding machine also contains the properties of low impact to the electrical net, energy saving, and high power factor.
Application of Resistance Welding Machine
● Automotive
● Aerospace
● Industrial Use
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