Introduction to the advantages and features of pulse welding
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1. Pulse welding concept
A pulse weld machine is a welding equipment that achieves welding by generating intermittent high-intensity pulse current. In traditional welding methods, current and heat are output continuously, which may cause overheating of the welding area and affect the welding quality. The pulse weld machine can generate intense heat in a short time by controlling the pulse time, frequency and amplitude of the current, but at the same time avoid overheating.
The core feature of the pulse weld machine is that it can accurately control the heat distribution during the welding process, which is particularly useful for some thin-walled materials or temperature-sensitive materials.
2. Characteristics of pulse welding
Pulse weld is a weld process that uses intermittent pulse current to control the heat output during the welding process. Compared with traditional continuous welding processes, pulse weld has higher flexibility and precision, which is very useful for welding complex materials or thin-walled components. The following are the main features and detailed explanation of pulse welding:
Intermittent current output: pulse weld uses intermittent high-intensity pulse current. This means that the current increases sharply for a short period of time and then stops or decreases. This intermittent output method makes the heat during welding easier to control and reduces the risk of overheating.
Precise heat control: Pulse weld can precisely control the heat during the welding process by adjusting the frequency, duration and current intensity of the pulse. This precision is ideal for welding thin-walled materials, electronic components and temperature-sensitive materials.
Reduce heat-affected zone: Since the pulse current is intermittent, the continuous input time of heat is shorter, thereby reducing the size of the heat-affected zone during the welding process. This means that the material deforms and stresses less during welding, and the structure after welding is more stable.
Versatility and applicability: Pulse weld is suitable for a variety of materials, including metals such as aluminum, copper, steel, titanium, and composites. This makes it widely used in many industries, including automotive manufacturing, aerospace, electronic equipment manufacturing and medical devices.
Reduced welding defects: Pulse weld reduces the continuous input of heat, thereby reducing the risk of welding defects such as burn-through, blow holes, cracks and other welding defects. This property is particularly important for applications requiring high precision and quality welding.
Improve welding accuracy: Since the heat output of pulse weld is intermittent, this makes the control during welding more precise. Welders can better control the shape and quality of welds and improve welding accuracy.
Energy conservation: Pulse weld, due to its intermittent output, may be more energy efficient than traditional continuous welding because it only outputs high-intensity current when needed.
3. Advantages of pulse welding
Compared with traditional DC or AC gas shielded welding, pulse welding has the following advantages:
ood arc starting performance: Since the pulse current has a high peak voltage, a stable arc can be easily excited on the surface of the workpiece.
Good adaptability of welding parameters to the workpiece being welded: Since the pulse parameters can be adjusted according to different materials, thickness, position and other factors, the best welding effect can be achieved.
The heat input is kept to a minimum: since only one drop of metal is ejected from the wire tip during each pulse cycle and solidifies in flight, the heat input is only related to the peak current and not to the base current. This reduces the size of the heat-affected zone, reducing deformation and residual stress.
Thicker wire can weld thinner workpieces: Since only one drop of metal is ejected from the tip of the wire during each pulse cycle and solidifies during flight, the diameter of the wire does not affect the size of the droplet, only the flight speed of the droplet. . This allows thicker welding wire to be used to weld thinner workpieces, improving welding efficiency and quality.
Less spatter throughout the pulse power adjustment zone: Since only one drop of metal is ejected from the wire tip during each pulse cycle and solidifies during flight, a large amount of spatter is not generated, even at high currents. This reduces cleanup and improves the appearance of the weld.
Good anti-porosity performance of the weld: Since only one drop of metal is ejected from the tip of the welding wire in each pulse cycle and solidifies during the flight, the gas in the droplet can escape easily without forming pores. And because the pulse current has a high peak voltage, it can break the oxide film on the surface of the molten pool and promote the discharge of gas.
Compared with DC welding, the melting efficiency of space welding is about 25% higher: since only one drop of metal is ejected from the tip of the welding wire in each pulse cycle and solidifies during the flight, the droplet has already melted before reaching the molten pool Most of the welding wire. DC welding requires melting the wire in a molten pool, which consumes more power. Therefore, the melting efficiency of pulse weld for space welds is about 25% higher than that of DC welding.
Good anti-corrosion performance: Since only one drop of metal is ejected from the tip of the welding wire in each pulse cycle and solidifies during the flight, the alloy elements in the droplet will not be oxidized and burned, and the original composition and properties are maintained. . DC welding requires melting the welding wire in the molten pool, which will lead to the loss and deterioration of alloy elements and reduce the corrosion resistance of the weld.
4. Disadvantages of pulse welding
Compared with traditional DC or AC gas shielded welding, pulse weld also has the following disadvantages:
High equipment cost: Due to the need to output pulse current, inverter technology and digital control technology need to be used, which will increase the complexity and cost of the equipment.
High operating technical requirements: Since the pulse parameters need to be adjusted according to different materials, thicknesses, positions and other factors, the operator needs to have a high technical level and experience, otherwise the best welding effect may not be achieved.
Sensitive to environmental interference: Due to the use of inverter technology and digital control technology, it is sensitive to environmental factors such as power supply fluctuations, temperature changes, and electromagnetic interference, which may affect the stability and reliability of the equipment.
5. Principle of pulse welding
(1) Pulse generator
The pulse generator is the core part of the pulse welding machine, which generates high-frequency pulse current. This current has a high frequency and short time intervals, which can heat the metal to a high enough temperature in a very short time.
(2) Welding head
The welding tip is the component connected to the pulse generator, which is responsible for transferring electrical current to the metal part. The welding head usually consists of two electrodes, one at the top and the other at the bottom. When two electrodes are brought close together, they form a small gap called a “discharge gap.”
(3) Metal parts
Metal parts are objects that need to be connected. When two metal parts are placed in the discharge gap, they are heated by a high-frequency pulse current.
(4) Welding process
During the welding process, the pulse generator generates high-frequency pulse current. These currents are transmitted to the metal part through the weld head and form an arc in the discharge gap. The arc heats the metal to a high enough temperature that it melts and forms a weld. When the pulse ends, the arc disappears and the metal begins to cool and solidify.
6. Pulse welding application fields
(1) Automobile manufacturing Pulse weld machines are widely used in automobile manufacturing for welding car bodies and other metal parts. This connection increases the strength and durability of the car.
(2) Aerospace Pulse weld machines are also widely used in the aerospace field. It can be used to weld aircraft parts such as engines, casings and fuel tanks.
(3) Construction In the field of construction, pulse weld machines can be used to connect steel structures, bridges and other metal structures. This connection increases the stability and durability of the building.
Machinery Manufacturing Pulse weld machines are also widely used in the field of machinery manufacturing. It can be used to connect various metal parts, such as bearings, gears and transmissions, etc.
