Resistance Welding and How it Applies to Modern Industrial Automation
Resistance welding is a process that utilizes electrically-produced heat as well as pressure in order to connect two separate materials. Although these specific processes generally refer to bonding metals, resistance welding can also pertain to plastic bonding as well. When done correctly, this kind of welding is considered both efficient and quick. Key mistakes made during resistance welding can lead to issues with cracking, cavities, and faulty surface appearance.The machines that are typically used in resistance welding use copper electrodes. As such, they’re used to inject specific materials with electrically produced heat. The operator of the machine has the ability to control the heating period as well as the amount of heat generated. Once enough heat is injected, then the materials can be cooled outside as the molten, inner materials are allowed to cool more slowly. The bonds will be created once this part is finished.
In general, the higher the degree of the metal’s melting point, the less heat is required. Any metal that’s a good heat conductor, like aluminum, needs additional heat when it comes to resistance welding since the heat is more inclined to infiltrate throughout the material rather than getting trapped at the metal’s melting point.
Also, resistance welding requires a great deal of force. Workers use pressure in order to hold metal layers together during the cooling process. Cohesion will likely never happen if this crucial step is ignored. The required pressure is generally applied by the same machine that provides the electrical current. The operator of the machine can also typically control how much pressure is used as well.
Resistance Welding and Industrial Automation
When it comes to industrial automation, the range of application includes a variety of dedicated machinery as well as turn-key plant solutions in the following areas: • Steel plate radiators • Structural profiles regarding the automotive industry • Heating plates • Kitchen ovens • Tubular radiators • Stainless steel sinks • Boilers • Condensers and compressors for refrigerators • Expansion tanks
Resistance welding technology also applies to projection welding, spot welding, and seam roll type welding machines. Incorporated wherever needed, these key technologies are fully integrated and equipped with highly advanced mechanical systems in order to provide every customer with the ideal automatic solution available in order to meet their specific needs.
Major industrial sectors with resistance welding applications• Domestic hardware • Food and drink • Medical instruments • Nuclear equipment • Radiator and container • Auto suppliers and automotive • Electronics and electrical • Airplane and aerospace • Rail and train carriage • Other industries
Other Welding Processes
One example of a common resistance welding process is spot welding. It’s used to bond multiple layers of metal together without the need for filler materials. Because copper is a great heat conductor, copper electrodes are used to securely clamp the metal layers together and then transmit electrical currents throughout.
On the other hand, a number of other metals aren’t such good conductors of heat. The heat generated within the project layers is thus trapped and leads to melting. Pressure stemming from the electrodes subsequently causes the layers to bond.
Seam welding is much like spot welding. But, rather than creating connections at a variety of points, this key process enables the formation of long, unbroken bonds. Also, round electrodes are utilized in this technique in order to adequately roll over the outside areas of the materials, thereby applying pressure and giving them electrical current.
Overall, there are many kinds of resistance welding bonds. A solid state bond is one that includes a minimal amount of melting. Fusion bonding, on the other hand, includes materials that bind together since their melting points are both reached, enabling the molten materials to easily combine.