Resistance Welders Prepared to Tackle the Most Demanding Jobs
The innovations taking place within the resistance welding market continue to make the process extremely cost efficient.
Posted: January 31, 2022
High-Duty DC Spot Welding Power Supply for High-Precision Applications
AMADA WELD TECH Europe (Puchheim, Germany) announces the DC-H3000A High Duty cycle, a high-performance DC resistance spot welding power supply for high precision micro-joining applications. It is designed for use in the medical device industry and other applications where accuracy, process control and traceability is required. The switching system architecture of this power supply provides unsurpassed levels of DC current purity, with ultra-low ripple and fast loop response, which enables it to react to, and control challenging applications, achieving a stated accuracy of +/- 1 percent of the controlled parameter set point. Precise pulsed output delivered to the weld is controlled in terms of either the peak voltage, current or power. The power supply also offers an intuitive touch screen display for easy access to the weld settings, data logging and communications functionality. It is equipped with USB, Ethernet, RS232 and conventional I/O communication ports for interfacing with control systems and/or capture of all welder performance data, which allows for simple automation and machine integration. The DC-H3000A interfaces directly with the AMADA WELD TECH WH-L090A Linear Motor Weld Head or pneumatically driven weld heads for improved process control.
MegaStir Friction Bit Joining Provides Alternative to Riveting
Mazak Corp.’s (Florence, KY) MegaStir has patented a new process known as Friction Bit Joining (FBJ). The process, like friction stir welding, gives manufacturers the ability to join two dissimilar metals without comprising their individual inherent properties or strengths. The new process is key to vehicle lightweighting. FBJ generates a powerful metallurgical bond between the process’ bit, which is a consumable, and the first and second metals, generating a solid-state joint that is flush on both sides.
In the automotive industry, in particular, the ability to join two dissimilar alloys is key to developing lighter vehicles that consume less energy, whether that’s fossil fuels or electricity. Other industries would also benefit from that same joining capability.
A typical FBJ system consists of a robotic arm and a process end-effector, and the Mazak MegaStir can customize this system to meet any customer’s specific needs. In operation, the robot arm moves the end-effector into position for performing the FBJ process. Shops with existing robots can easily adapt them for FBJ, with Mazak MegaStir providing just the bits and end-effector to create a fully functional system.
The consumable bits used in FBJ allow users to fuse the bit, the top material and the bottom material together in a matter of seconds. As the bit rotates, it generates heat that, in the end, forms a joint comprised of all three materials, promoting even flow from the top material to the bottom material in a smooth simultaneous piercing and stirring action for solid-state joining.
New Essential Series Resistance Spot, Seam and Flash Welders
Taylor-Winfield Technologies Inc. (Youngstown, OH) a world leader in the design and manufacture of resistance welding equipment, introduces the Essential Series, a pre-packaged, off-the-shelf economically priced option for the resistance welding marketplace. The Essential Series offers many configurations for spot/projection, seam, rocker arm and flash butt welders for all types of metal joining applications.
Taylor-Winfield Technologies will continue to offer the Signature Series of resistance welders, which are the robust, customizable welders. Whether you are looking for a standalone, manual welder or completely automated custom resistance welding solution, Taylor-Winfield can design and build a one-of-a-kind machine or system to meet your production requirements.
Options for customizing the Signature Series includes throat length, welder configurations, transformer size, control options, cylinder size, welder stroke, platen size, fast follow-up, custom tooling, ram configurations and more.
Taylor-Winfield’s resistance welding machines can be found in metal processing and parts production factories throughout the world and offer a welding solution for just about any application. As one of the first companies to master resistance welding technology, Taylor-Winfield helped write the process specifications found in the Resistance Welding Manufacturing Alliance’s manual and many other welding textbooks, and parts joining requirements.
T.J. Snow Co. (Chattanooga, Tenn.) is the largest stocking distributor of TECNA portable and stationary resistance spot welders in the United States. Made in Italy, the value priced TECNA product line includes a complete range of machines for spot and projection welding.
The small models of TECNA spot welders have become increasingly popular in recent years because Miller Electric obsoleted its line of 10 and 20 KVA machines that were popular with sheet metal shops.
TECNA portable gun-style spot welders are unique because the programmable welder control is built into the gun’s handle. Other brands of portable spot welders require a separate control, which must be remote mounted on a wall or pedestal. To facilitate a full range of motion, TECNA portable spot-welding guns can be matched to a properly sized TECNA spring balancer.
TECNA stationary spot welders include rocker arm and vertical press-type machines of various KVA ratings. One of the most popular TECNA welders is the Model 6128N, a versatile 160 KVA press-type combination projection and spot welder with a Mid Frequency Direct Current (MFDC) power supply.
The welder is equipped with a sophisticated Model TE-700 control, which includes constant current and a dynamic mode, which allows the weld schedule to adjust on the fly. To make the selection of the ideal TECNA welder easy, T. J. Snow invites customers to send samples for welding in its lab.
