What are the technical parameters of flash butt welding machine?

Flash butt welding. The process parameters of the machine, including extension length, flash current, flash speed, flash flow, top forging pressure, top forging current, top forging flow, top forging speed, fixture clamping force, preheating temperature, preheating time, etc. Let's take a look at it.

Flash flow: when selecting the flash retention, it should be satisfied that there is a layer of molten metal on the end face of the entire weldment at the end of the flash, and at the same time the plastic deformation temperature is reached at a certain depth, the flash flow is too small, which will affect the welding quality, waste metal materials and reduce productivity, and when the flash flow rate is selected, the preheating flash butt welding is 30%-50% smaller than the continuous flash butt welding.

Flash current: During flash butt welding, the current passing through the weldment during the flash phase depends on the physical properties of the metal to be welded, the flash speed, the area and shape of the weldment end face, and the heating state, with the increase of the flash speed, the flash current increases.

Flash speed: with a large enough flash speed to ensure the intensity and stability of the flash, but the flash speed is too large, the heating zone will be too narrow, increase the difficulty of plastic deformation, therefore, the flash speed should be based on the characteristics of the welded material, in order to ensure that the end face to obtain a uniform metal melting layer as the standard, in general, the material with good electrical and thermal conductivity flash speed is larger.

Forging pressure: Generally, the top forging pressure is used to express, and the size of the top forging pressure should ensure that the liquid metal in the interface can be extruded.

And at the joint produces a certain plastic deformation, but also depends on the performance of the metal, temperature distribution characteristics, forging flow and forging speed, workpiece end face shape and other factors, the top forging pressure is too large, the deformation is too large, will reduce the impact toughness of the joint.

If the top forging pressure is too low, the deformation is insufficient, and the strength of the joint decreases.

Jacking forging flow: the size of the jacking forging flow affects the removal of liquid metal and the size of plastic deformation, the jacking flow is too large, reducing the impact toughness of the joint, too small so that the liquid metal remains in the interface, easy to form looseness, shrinkage holes, cracks and other defects, the jacking forging flow should be selected according to the cross-sectional area of the workpiece, and increase with the increase of the weldment section.

Top-forging speed: In general, the faster the top-forging speed, the better, the top-forging speed depends on the performance of the weldment material, such as the minimum top-forging speed of welding austenitic steel is about twice that of pearlitic steel, and the good thermal conductivity of hungry metals requires a higher top-forging speed.

Fixture and clamping force: It must be ensured that the whole welding process does not slip, and it is necessary to ensure that it is not skidding, and the friction between the welding part and the fixture.

Relate. Preheating temperature: The preheating temperature is selected according to the size of the weldment section and the nature of the material, for mild steel.

Generally not more than 700-900, the preheating temperature is too high, due to the overheating of the material to reduce the impact toughness and plasticity of the joint, when welding large cross-section weldments, the preheating temperature should be increased accordingly.

This asks the professionals, I am not clear, you go and ask you!

Summary. Hello, to choose the parameters of the welding machine, to consider the current during welding, the maximum current carrying capacity of the transformer, and then you can choose the parameters of the welding machine according to your own workpiece, basically the technical parameters of the welding machine manufacturers are the same.

The main parameters of flash butt welding are: extension length, flash current, flash flow, flash speed, top forging flow, top forging speed, top forging pressure, top forging current, clamp clamping force, etc.

The flash current if and the topforging current IUIF depend on the cross-sectional area of the workpiece and the current density required for the flash, which are also related to the physical properties of the welded metal, the flash speed, the area and shape of the cross-section of the workpiece, and the heating state of the end face. During the flashing process, JF will increase as the VF gradually increases and the contact resistance RC decreases. When the top forging is performed, the RC disappears rapidly, and the current will increase sharply to the top forging current IU.

When welding large cross-section steel, in order to increase the heating depth of the workpiece, a small flash speed should be used, and the average JF used is generally not more than 5A mm2.

The size of the forging pressure should ensure that the liquid metal in the interface can be extruded, and a certain plastic deformation will be produced at the joint. If the top forging pressure is too small, the deformation is insufficient and the strength of the joint decreases; If the top forging pressure is too large, the deformation will be too large, the crystal bending will be serious, and the impact toughness of the joint will be reduced.

Flash speed vf is large enough to ensure the intensity and stability of the flash.

How to choose flash butt welding machine parameters.

This question is up to me, it takes a little time to type, so please be patient.

You have a good base shed, choose the parameters of the welding machine, consider the current during welding, the maximum current carrying capacity of the transformer, and then you can choose the parameters of the welding machine according to your own workpiece, basically the technical parameters of the welding machine manufacturers are the same.

The main parameters of flash butt welding are: extension length, virtual flash differential branch grip current, flash flow, flash speed, tie top forging flow, top forging speed, top forging pressure, top forging current, clamp clamping force, etc.

The flash current IF and the jacking current IUIF depend on the cross-sectional area of the workpiece and the current density required for the flash, which are also related to the physical properties of the welded metal, the flash speed, the area and shape of the cross-sectional surface of the workpiece, and the heating state of the seepage hood of the end face. During the flashing process, JF will increase as the VF gradually increases and the contact resistance RC decreases. When the top forging is bent, RC disappears quickly, and the current cluster will increase sharply to the top forging current IU.

When welding large cross-section steel, in order to increase the heating depth of the workpiece, a small flash speed should be used, and the average JF used is generally not more than 5A mm2.

The size of the top forging pressure should ensure that the liquid metal in the interface can be extruded, and a certain plastic deformation will be produced at the head of the sail catcher. If the top forging pressure is too small, the deformation is insufficient, and the strength of the joint decreases. If the top forging pressure is too large, the deformation will be too large, the crystal bending will be serious, and the impact toughness of the joint will be reduced.

Flash speed vf is large enough to ensure the intensity and stability of the flash.

Definition of flash butt welding.

The essence of the formation of the flash welding joint is that the metal is recrystallized on the joint surface under high-temperature plastic deformation to produce common grains and form joints. Resistance butt welding is mainly heated by the resistance of the workpiece itself, while flash butt welding must be heated by the flash process by the contact resistance heat generated during the flash.

The principle of flash butt welding.

The device for flash butt welding is the same as resistance welding, with only slight contact (contact at individual points) of the workpiece at the start of welding. When an electric current is passed through the contact point, the metal near the contact point is strongly heated and melted. The molten metal is shot out of the interface in the form of a spark, the workpiece continues to move closer, and the contact points are constantly generated, forming a continuous spark emission; At the same time, the workpiece joint is also heated strongly, so that the end face of the workpiece is completely melted.

When heated to a high enough temperature within a certain depth from the end face, pressure is quickly applied to connect them together.

Flash butt welding classification.

Flash butt welding is divided into two types: continuous glazing butt welding and preheating flash butt welding.

Continuous flash butt welding consists of two main stages: the flash stage and the top forging stage.

The preheating flash butt welding preheating stage, the flash stage, and the top forging stage consist of three main stages.

At the end of heating, the temperature distribution along the workpiece axis of resistance butt welding and flash butt welding varies, with resistance butt welding having a more uniform temperature distribution, while continuous butt welding has the steepest temperature distribution and preheating flash butt welding is somewhere in between.

Features of flash butt welding.

1. It has a wide range of use, can weld the same or different metals, and the cross-sectional area of the weldable workpiece is larger than that of resistance butt welding.

2. The molten metal layer or oxide on the joint surface is extruded at the top, which can play a role in removing impurities on the joint surface, so the preparation and cleaning requirements for the surface of the workpiece are not strict.

3. The joint has high reliability and strength.

4. The joint is narrow in the heat-affected zone, and the workpiece is less affected by heat, which reduces the tendency to produce defects.

5. During butt welding, the molten metal particles sprayed out have certain dangers.

6. After welding, burrs are formed at the joints, and necessary follow-up processes are required for treatment.

Rated capacity: 125kva.

Frequency: 50hz Welding chain ring diameter: 6mm-10mm.

Motor (brake) JEJ32-4 frequency conversion stepless speed regulation.

Flash butt welding is widely used for longitudinal connection of steel bars and welding of prestressed steel bars and screw end rods. The principle of flash butt welding of steel bars is to use the butt welding machine to make the steel bars at both ends contact, through the strong current of low voltage, after the steel bars are heated to a certain temperature and softened, the axial pressure top forging is carried out to form a butt welding joint.

Continuous flash welding, preheating flash welding, and flash-preheating-flash welding are commonly used in the steel flash butt welding process. Grade steel bars are sometimes heated with electricity after welding.

Please provide me with the model of the welding machine is the UN series? Copper-clad aluminum-clad.

Input current, output current.

I'll send you the details.

UN series flash butt welding machine, in fact, you don't have to ask, if you want to find a welding machine, you can go to a professional welding equipment company, they will choose a suitable set of flash butt welding machine for you according to your requirements What model is not important, the important thing is to meet the requirements of your product.

1. The models of flash butt welding machines commonly used in steel bar welding include un-75, un-100, un-150, un-150-1, etc.; The specific parameters are as follows:

2. Technical parameters of spot welding machine (single-head, multi-head).

3. Arc welding machine, electroslag pressure welding, pneumatic pressure welding, submerged arc pressure welding and other equipment can be used for steel bar welding.

There should be no problem with the butt welding machine of 100 and 25 steel bars, if it is unqualified, it may be that the voltage and current cannot be reached, and you can do the butt welding test again at night without other high-power equipment running.

Flash butt welding machine is one of the welding machines often used in many enterprises, the principle is not unfamiliar to many people, but how to operate may not be well understood by many people, so in view of this situation, it is necessary for us to master some of the correct use of Suzhou Anjia flash butt welding machine:

When operating, you need to pay attention to the condition of the equipment, the spot welding machine will have a stable exhaust, downward pressure, discharge and other sounds, once it is found that the machine is running slowly, sluggish, making a strange sound or the equipment itself alarms, it needs to be closed in time for inspection. The reason for this can be because of a failure of the internal parts of the machine or a change in external conditions, which can cause more damage if not addressed in time.

Because the contact area of the electrode directly determines the current density, and the resistivity and thermal conductivity of the electrode material are directly related to the generation and loss of heat, the shape of the electrode has a huge impact on the formation of the nugget.

The thickening of oxides, dirt, oil and other impurities on the surface of the workpiece affects the resistance, the excessively thick oxide layer will make the current can not be passed, the local conduction, due to the excessive current density, will produce spatter and surface burning, the existence of the oxide layer will also affect the unevenness of the heating of each solder joint, causing the fluctuation of welding current, so it is necessary to thoroughly clean the surface of the workpiece to ensure that the high-quality joint is obtained.

The lead wire of the welding machine should not be too long, the voltage drop during welding shall not be greater than 5% of the initial voltage, the initial voltage shall not deviate from the power supply voltage by 10%, the operator should wear gloves, protective clothing, insulating shoes, goggles to avoid sparks splashing eyes, the sliding part should ensure good lubrication, and the metal splash should be clear after use.

b) At least two specimens are broken outside the weld and are ductile fractured.

When the test result has the tensile strength of 1 specimen is less than the above-mentioned specified value, or there are 2 specimens in the weld or heat-affected zone brittle and slow fracture, 6 specimens should be taken again for re-inspection. The results of the re-inspection show that when the tensile strength of 1 specimen is less than the specified value, or 3 specimens are broken in the weld or heat-affected dry area, showing brittle fracture, it should be confirmed that the batch of joints is unqualified.

c) The tensile test results of the flash pair of the prestressed steel bar and the screw end rod on the welding joint, the three specimens should all be broken outside the weld and show ductile fracture.

When the test results show that one specimen has a brittle fracture in the weld or the affected zone of the thermal mold, three more specimens should be cut from the finished product for re-inspection. If there is still one specimen brittle fracture in the weld or heat-affected zone, it should be confirmed that the batch of joints is unqualified.