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A complete set of operation methods for joint quality adjustment based on butt welding workpieces
Wuxi Xinxing Welding Equipment Factory mainly produces: spot welding machines, butt welding machines, flash butt welding machines, medium frequency spot welding machines, energy storage spot welding machines, nut spot welding machines, polymer diffusion welding machines and other resistance welding equipment! QQ online consultationSitemapContact us
Xinxing. Intelligent resistance welding equipment and solution service provider 33 years of deep experience in the industry help companies solve difficult welding problems and improve welding efficiency!
National service hotline:400-001-050213395100070
A complete set of operation methods for joint quality adjustment based on butt welding workpieces
Release time:2021.09.08
Summary of information:
Many people cannot find the manual within a month after buying a butt welding machine, and when they encounter problems with welding joints, they are too embarrassed to call the welding machine manufacturer for help. To address this problem, the editor has made an article about solutions based on the quality of butt welding joints to facilitate inquiries.
Wuxi Xinxing Welding Equipment Factory originated fromIn 1993, focused on resistance welding machinesButt welding machineIn the past 30 years, the quality problems of butt welding joints have been summarized as follows:
Check the joint quality adjustment operation method table for butt welding workpieces
|
serial number |
phenomenon |
main reason |
Adjustment method |
|
1. |
Overheating or overwelding |
Flash speed and upsetting allowance are too small |
1、Adjust welding parameters 2、Partial normalization treatment removal of over-soldering |
|
Preheating too long |
|||
|
The upsetting speed is too slow and the time is too long |
|||
|
The upsetting force is too large or the time is too long |
|||
|
2. |
The tissue is too loose and shrinkage |
The no-load voltage is too high and the fire mouth is deep |
Adjust welding parameters |
|
The upsetting amount is small and the force is small |
|||
|
Upsetting speed is too slow |
|||
|
The welding point is uneven and the base metal has a wide dual-phase zone. |
|||
|
3. |
Dark spots and mixed oxides |
The welding joint is heated unevenly and the internal melting degree is insufficient. |
Adjust welding parameters |
|
The upsetting amount is small and the force is small |
|||
|
Flash ends slowly |
|||
|
The flash is discontinuous, especially when the power is cut off before upsetting. |
|||
|
4. |
Vertical or circular cracks on the surface |
Elastic deformation of parts of clamping and upsetting mechanisms |
Replace parts or add rigidity |
|
Movable pallet moves backward prematurely |
Adjust welding parameters |
||
|
Part temperature is too high |
|||
|
Electric upsetting takes too long |
|||
|
5. |
parallel cracks |
There is slag inclusion or interlayer in the workpiece |
Adjust welding parameters |
|
During over welding, the upsetting amount is small and the force is small |
|||
|
Insufficient heating results in large upsetting volume and high strength. |
|||
|
6. |
Not penetrated |
Preheating time is too short or preheating temperature is too low |
Adjust welding parameters |
|
Upsetting speed is too slow |
|||
|
1. No-load voltage is too small 2. The electric upsetting time is too short 3. The flash speed is too fast 4. Too little flash left 5. Too little upsetting allowance |
|||
|
2. The joint between the workpieces is unclean or uneven. |
Clean the surface, make it smooth, and repair it with shielded welding |
||
|
7. |
superficial burns |
Clamping force is too small |
Increase clamping force |
|
Electrode wear or poor conductivity |
Replace electrodes |
||
|
There are stains on the surface of the electrode and workpiece |
Clean the surface |
||
|
Part size is not standard |
trim size |
||
|
8. |
There are deviations in size |
The heating allowance and upsetting allowance are insufficient or unstable |
Adjust welding parameters, repair equipment and controllers |
|
9. |
Centerline deviation/form and position out of tolerance |
Electrode wear or deformation |
Replace electrodes |
|
1. The travel track of the movable pallet is not standardized, the guide rail gap is too large or the rigidity is not strong, 2. The clamping mechanism is deformed |
Replace parts or add rigidity |
||
|
Inaccurate clamping of welding machine parts |
Re-clamp |
||
|
1. The extension length is too long 2. The upsetting amount and force are too large |
Adjust parameters |
||
|
1. The workpiece is bent 2. The end face is uneven |
Correction |
Wuxi Xinxing Welding Equipment Factory originated fromIn 1993, the company focused on resistance welding machines for decadesWelding machine manufacturer,Production products include: spot welding machine, butt welding machine, flash welding machinewelding machine, medium frequency spot welding machine, energy storage spot welding machine, nut spot welding machine, row welding machine, automatic welding machine, multi-strand wire welding machine, cage bone welding machine, special customized welding machine, etc., reaching more than 300 kinds, the quality is comparable to imported products.Welcome to buy!
Hot product recommendations
-
300KVA copper bar soft connection diffusion welding machine
Power: 300KVA Model: DBTH-300 Overlap: Copper skin, copper strip, copper foil soft connection, stainless steel, etc., and can also weld dissimilar materials. The hydraulic high-power medium-voltage medium-frequency copper bar soft connection diffusion welding machine mainly welds the same multi-layer copper strip, copper foil and copper skin into soft and hard copper bar connectors. It can also weld stainless steel strips, titanium zirconium and tantalum strips and multi-layer dissimilar materials. Mainly used for conductive connections in new energy vehicles, electric power stations, electrical switches, smelting power supplies, welding machines and other industries.
-
150KVA copper strip soft connection diffusion welding machine
Power: 150KVA Model: DBTH-150 Overlap: soft connection of copper skin and copper strip, stainless steel, etc., and can also weld dissimilar materials. The variable frequency polymer diffusion welding machine is a welding method that brings the surfaces of workpieces into contact with each other under a certain temperature and pressure, causing a fine liquid phase to be produced on the surface of the workpiece and gradually diffusing each other to achieve bonding. It is mainly used for soft connections of new energy vehicle batteries, soft copper bar connections of power supplies, secondary output connections of large power supplies in petrochemical industry, smelting, welding machine connection copper strip joints, etc.
-
SUN pneumatic automatic flash butt welding machine
1. Originated in 1993 2. Xinxing’s 26-year history 3. Always adhere to all-copper welding machines 4. 10-year long design life 5. 20-year service life record 6. Serve 4000+ customers 7. CQC certified products
-
UN6 flash pneumatic resistance butt welding machine
The UN6 flash pneumatic resistance butt welding machine is widely used in the butt jointing of various metal round materials, flat materials, and pipes. With different special molds, it can also weld various special-shaped materials and copper and aluminum pipe joints. The UN6 flash pneumatic butt welding machine adopts pneumatic clamping and pneumatic transverse upsetting. It is also equipped with a special butt welding controller, which can accurately adjust the welding current and welding time. The welding output can be configured as required and adopts two control methods, primary voltage feedback and secondary current feedback, to ensure consistent welding current. Just step on the foot switch to complete the entire welding process. The machine has a high degree of automation and stable welding quality. Compared with the previous standard version, the welding stroke limit and upsetting air pressure conversion functions have been updated. The non-standard version is controlled by PLC programmer, and can be equipped with optional tempering device, ejector cylinder, and positioning cylinder auxiliary action. In addition to the above extended functions, the high-end version adopts modular design and linear guide rail guidance for higher precision and easier maintenance. Please read below for advantages and features
-
DBZ medium frequency resistance spot welding machine
Xinxing medium frequency inverter pneumatic resistance spot welding machine is a three-phase alternating current that is rectified into DC, and then through an inverter circuit composed of IGBT power devices, it is converted into an intermediate frequency 1000-4000HZ AC square wave output. After being stepped down by a transformer, it is rectified into DC and supplied to the electrode for welding the workpiece. Current feedback and pulse width modulation (PWM) are used to obtain stable current output. It is one of the cutting-edge resistance welding methods today. The medium-frequency resistance spot welding machine can be used for spot welding and multi-point projection welding of ordinary low carbon steel plates, stainless steel plates, galvanized sheets, aluminum plates and wires. It can also be used for spot welding and nut projection welding of high-strength steel and hot-formed steel in the automobile manufacturing industry, as well as resistance brazing and spot welding of copper wires in the high and low voltage electrical industry, brazing of silver points and copper plates, composite silver point welding, etc. Please read below for advantages and features
-
Semi-automatic CNC UN2S copper rod resistance butt welding machine butt welding machine
1. This series of products ranks top 2 in the national market share 2. Originated in 1993 3. Xinxing’s 28-year history 4. Always adhere to all-copper welding machines 5. 10-year long design life 6. 20+ years service life 7. Serve 5000+ customers 8. CQC certified products 9. 90% repeat customers
-
160KVA copper stranded wire pneumatic butt welding machine
Model: UNG-160 Power: 160kva Butt: 50~300 square meters of copper stranded wire, aluminum stranded wire, copper rod, aluminum rod 160KVA copper stranded wire butt welding machine adopts pneumatic pressurization, photoelectric positioning, touch screen programming control, water cooling, low-voltage and high-current intelligent resistance welding machine, and welds copper multi-strand wires and aluminum multi-strand wires with sleeves Wire, stranded conductor, welded firmly in 2 seconds, smooth and without flash. Please read below for advantages and features
-
UNG precision multi-stranded copper wire butt welding machine
Model: UNG-5 Power: 5Kva Suitable for: rapid welding of multi-stranded conductors, copper strands, tinned copper strands, and aluminum strands in wire and cable factories. The UNG precision multi-stranded wire butt welding machine is a single-phase AC resistance butt welding machine. This welding machine is mainly used for welding multi-strand conductors in the wire and cable industry. It is used with casings and is welded and formed in one go. The joints are strong and beautiful, with no flash or burrs, and the wire diameter does not change. It can be directly threaded through the mold, so that the production can be changed without stopping the machine.
-
CNC type UNG multi-stranded wire butt welding machine butt welding machine
Model: UNG-5 Power: 5KVA CNC UNG multi-strand wire butt welding machine belongs to the single-phase AC resistance butt welding machine category. This welding machine can butt weld 0.75-10 square meters of copper multi-stranded wires, 4-16 square meters of aluminum multi-strand wires and various metal wires, such as steel wires, copper wires, aluminum wires, titanium alloy wires, etc. It is suitable for the welding of round rods and small wires in wire drawing, cable and metal wire processing industries. 1. Xinxing’s 30-year history 2. Always adhere to all-copper welding machines 3. 10-year long design life 4. 20+ years of service life 5. Serving 11,000+ customers 6. CE certified products 7. 90% are repeat customers
-
50KVA pneumatic multi-stranded wire butt welding machine
Model: UNG-50 Power: 50KVA Butt connection: 16-120 square copper stranded wire, 25-120 square aluminum stranded wire, tinned stranded wire φ4-12 copper rod φ4-16 aluminum rod Pneumatic multi-strand wire butt welding machine is one of the resistance welding machines (butt welding machines). A pneumatic butt welding machine developed by Xinxing Welding Equipment Factory in 2005. It adopts pneumatic clamping and pneumatic transverse upsetting, and is equipped with an internal and external full water cooling system and a special butt welding controller, which can accurately adjust parameters. At the same time, it can be used with casings to weld multi-core wire harnesses and single-core copper wires without burrs.
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Contact Xinxing
- After-sales phone number:400-001-0502
- Pre-sales phone number:199-5222-1801
- Email:cnhjsb@163.com
- Address:Next to Huaming Bridge, 161 kilometers away from National Highway 312, Luoshe Town, Huishan District, Wuxi City, Jiangsu Province
Wuxi Xinxing Welding Equipment FactoryAll rights reserved
Su Public Network Security No. 32020602001105Su ICP No. 11039752
Service hotline 400-001-050213395100070 new manager
Email:cnhjsb@163.com
Factory address: Huishan District, Wuxi City, Jiangsu ProvinceHuamingqiao Industrial Zone, 161 kilometers away from National Highway 312, Luoshe Town, Huishan District, Wuxi City, Jiangsu Province
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A complete set of operation methods for joint quality adjustment based on butt welding workpieces
Release time:2021.09.08
Summary of information:
Many people cannot find the manual within a month after buying a butt welding machine, and when they encounter problems with welding joints, they are too embarrassed to call the welding machine manufacturer for help. To address this problem, the editor has made an article about solutions based on the quality of butt welding joints to facilitate inquiries.
Wuxi Xinxing Welding Equipment Factory originated fromIn 1993, focused on resistance welding machinesButt welding machineIn the past 30 years, the quality problems of butt welding joints have been summarized as follows:
Check the joint quality adjustment operation method table for butt welding workpieces
|
serial number |
phenomenon |
main reason |
Adjustment method |
|
1. |
Overheating or overwelding |
Flash speed and upsetting allowance are too small |
1、Adjust welding parameters 2、Partial normalization treatment removal of over-soldering |
|
Preheating too long |
|||
|
The upsetting speed is too slow and the time is too long |
|||
|
The upsetting force is too large or the time is too long |
|||
|
2. |
The tissue is too loose and shrinkage |
The no-load voltage is too high and the fire mouth is deep |
Adjust welding parameters |
|
The upsetting amount is small and the force is small |
|||
|
Upsetting speed is too slow |
|||
|
The welding point is uneven and the base metal has a wide dual-phase zone. |
|||
|
3. |
Dark spots and mixed oxides |
The welding joint is heated unevenly and the internal melting degree is insufficient. |
Adjust welding parameters |
|
The upsetting amount is small and the force is small |
|||
|
Flash ends slowly |
|||
|
The flash is discontinuous, especially when the power is cut off before upsetting. |
|||
|
4. |
Vertical or circular cracks on the surface |
Elastic deformation of parts of clamping and upsetting mechanisms |
Replace parts or add rigidity |
|
Movable pallet moves backward prematurely |
Adjust welding parameters |
||
|
Part temperature is too high |
|||
|
Electric upsetting takes too long |
|||
|
5. |
parallel cracks |
There is slag inclusion or interlayer in the workpiece |
Adjust welding parameters |
|
During over welding, the upsetting amount is small and the force is small |
|||
|
Insufficient heating results in large upsetting volume and high strength. |
|||
|
6. |
Not penetrated |
Preheating time is too short or preheating temperature is too low |
Adjust welding parameters |
|
Upsetting speed is too slow |
|||
|
1. No-load voltage is too small 2. The electric upsetting time is too short 3. The flash speed is too fast 4. Too little flash left 5. Too little upsetting allowance |
|||
|
2. The joint between the workpieces is unclean or uneven. |
Clean the surface, make it smooth, and repair it with shielded welding |
||
|
7. |
superficial burns |
Clamping force is too small |
Increase clamping force |
|
Electrode wear or poor conductivity |
Replace electrodes |
||
|
There are stains on the surface of the electrode and workpiece |
Clean the surface |
||
|
Part size is not standard |
trim size |
||
|
8. |
There are deviations in size |
The heating allowance and upsetting allowance are insufficient or unstable |
Adjust welding parameters, repair equipment and controllers |
|
9. |
Centerline deviation/form and position out of tolerance |
Electrode wear or deformation |
Replace electrodes |
|
1. The travel track of the movable pallet is not standardized, the guide rail gap is too large or the rigidity is not strong, 2. The clamping mechanism is deformed |
Replace parts or add rigidity |
||
|
Inaccurate clamping of welding machine parts |
Re-clamp |
||
|
1. The extension length is too long 2. The upsetting amount and force are too large |
Adjust parameters |
||
|
1. The workpiece is bent 2. The end face is uneven |
Correction |
Wuxi Xinxing Welding Equipment Factory originated fromIn 1993, the company focused on resistance welding machines for decadesWelding machine manufacturer,Production products include: spot welding machine, butt welding machine, flash welding machinewelding machine, medium frequency spot welding machine, energy storage spot welding machine, nut spot welding machine, row welding machine, automatic welding machine, multi-strand wire welding machine, cage bone welding machine, special customized welding machine, etc., reaching more than 300 kinds, the quality is comparable to imported products.Welcome to buy!
Hot product recommendations
-
300KVA copper bar soft connection diffusion welding machine
Power: 300KVA Model: DBTH-300 Overlap: Copper skin, copper strip, copper foil soft connection, stainless steel, etc., and can also weld dissimilar materials. The hydraulic high-power medium-voltage medium-frequency copper bar soft connection diffusion welding machine mainly welds the same multi-layer copper strip, copper foil and copper skin into soft and hard copper bar connectors. It can also weld stainless steel strips, titanium zirconium and tantalum strips and multi-layer dissimilar materials. Mainly used for conductive connections in new energy vehicles, electric power stations, electrical switches, smelting power supplies, welding machines and other industries.
-
150KVA copper strip soft connection diffusion welding machine
Power: 150KVA Model: DBTH-150 Overlap: soft connection of copper skin and copper strip, stainless steel, etc., and can also weld dissimilar materials. The variable frequency polymer diffusion welding machine is a welding method that brings the surfaces of workpieces into contact with each other under a certain temperature and pressure, causing a fine liquid phase to be produced on the surface of the workpiece and gradually diffusing each other to achieve bonding. It is mainly used for soft connections of new energy vehicle batteries, soft copper bar connections of power supplies, secondary output connections of large power supplies in petrochemical industry, smelting, welding machine connection copper strip joints, etc.
-
SUN pneumatic automatic flash butt welding machine
1. Originated in 1993 2. Xinxing’s 26-year history 3. Always adhere to all-copper welding machines 4. 10-year long design life 5. 20-year service life record 6. Serve 4000+ customers 7. CQC certified products
-
UN6 flash pneumatic resistance butt welding machine
The UN6 flash pneumatic resistance butt welding machine is widely used in the butt jointing of various metal round materials, flat materials, and pipes. With different special molds, it can also weld various special-shaped materials and copper and aluminum pipe joints. The UN6 flash pneumatic butt welding machine adopts pneumatic clamping and pneumatic transverse upsetting. It is also equipped with a special butt welding controller, which can accurately adjust the welding current and welding time. The welding output can be configured as required and adopts two control methods, primary voltage feedback and secondary current feedback, to ensure consistent welding current. Just step on the foot switch to complete the entire welding process. The machine has a high degree of automation and stable welding quality. Compared with the previous standard version, the welding stroke limit and upsetting air pressure conversion functions have been updated. The non-standard version is controlled by PLC programmer, and can be equipped with optional tempering device, ejector cylinder, and positioning cylinder auxiliary action. In addition to the above extended functions, the high-end version adopts modular design and linear guide rail guidance for higher precision and easier maintenance. Please read below for advantages and features
-
DBZ medium frequency resistance spot welding machine
Xinxing medium frequency inverter pneumatic resistance spot welding machine is a three-phase alternating current that is rectified into DC, and then through an inverter circuit composed of IGBT power devices, it is converted into an intermediate frequency 1000-4000HZ AC square wave output. After being stepped down by a transformer, it is rectified into DC and supplied to the electrode for welding the workpiece. Current feedback and pulse width modulation (PWM) are used to obtain stable current output. It is one of the cutting-edge resistance welding methods today. The medium-frequency resistance spot welding machine can be used for spot welding and multi-point projection welding of ordinary low carbon steel plates, stainless steel plates, galvanized sheets, aluminum plates and wires. It can also be used for spot welding and nut projection welding of high-strength steel and hot-formed steel in the automobile manufacturing industry, as well as resistance brazing and spot welding of copper wires in the high and low voltage electrical industry, brazing of silver points and copper plates, composite silver point welding, etc. Please read below for advantages and features
-
Semi-automatic CNC UN2S copper rod resistance butt welding machine butt welding machine
1. This series of products ranks top 2 in the national market share 2. Originated in 1993 3. Xinxing’s 28-year history 4. Always adhere to all-copper welding machines 5. 10-year long design life 6. 20+ years service life 7. Serve 5000+ customers 8. CQC certified products 9. 90% repeat customers
-
160KVA copper stranded wire pneumatic butt welding machine
Model: UNG-160 Power: 160kva Butt: 50~300 square meters of copper stranded wire, aluminum stranded wire, copper rod, aluminum rod 160KVA copper stranded wire butt welding machine adopts pneumatic pressurization, photoelectric positioning, touch screen programming control, water cooling, low-voltage and high-current intelligent resistance welding machine, and welds copper multi-strand wires and aluminum multi-strand wires with sleeves Wire, stranded conductor, welded firmly in 2 seconds, smooth and without flash. Please read below for advantages and features
-
UNG precision multi-stranded copper wire butt welding machine
Model: UNG-5 Power: 5Kva Suitable for: rapid welding of multi-stranded conductors, copper strands, tinned copper strands, and aluminum strands in wire and cable factories. The UNG precision multi-stranded wire butt welding machine is a single-phase AC resistance butt welding machine. This welding machine is mainly used for welding multi-strand conductors in the wire and cable industry. It is used with casings and is welded and formed in one go. The joints are strong and beautiful, with no flash or burrs, and the wire diameter does not change. It can be directly threaded through the mold, so that the production can be changed without stopping the machine.
-
CNC type UNG multi-stranded wire butt welding machine butt welding machine
Model: UNG-5 Power: 5KVA CNC UNG multi-strand wire butt welding machine belongs to the single-phase AC resistance butt welding machine category. This welding machine can butt weld 0.75-10 square meters of copper multi-stranded wires, 4-16 square meters of aluminum multi-strand wires and various metal wires, such as steel wires, copper wires, aluminum wires, titanium alloy wires, etc. It is suitable for the welding of round rods and small wires in wire drawing, cable and metal wire processing industries. 1. Xinxing’s 30-year history 2. Always adhere to all-copper welding machines 3. 10-year long design life 4. 20+ years of service life 5. Serving 11,000+ customers 6. CE certified products 7. 90% are repeat customers
-
50KVA pneumatic multi-stranded wire butt welding machine
Model: UNG-50 Power: 50KVA Butt connection: 16-120 square copper stranded wire, 25-120 square aluminum stranded wire, tinned stranded wire φ4-12 copper rod φ4-16 aluminum rod Pneumatic multi-strand wire butt welding machine is one of the resistance welding machines (butt welding machines). A pneumatic butt welding machine developed by Xinxing Welding Equipment Factory in 2005. It adopts pneumatic clamping and pneumatic transverse upsetting, and is equipped with an internal and external full water cooling system and a special butt welding controller, which can accurately adjust parameters. At the same time, it can be used with casings to weld multi-core wire harnesses and single-core copper wires without burrs.