butt welding machines butt welder

According to the working principle of butt welding machines, butt welding processes can be divided into two types: resistance butt welding and flash butt welding:

Resistance butt welding is the process of heating the end joints of steel bars to a plastic state, cutting off the power supply, and then heating them to achieve a plastic connection. This welding process is prone to oxidation and slag inclusion at the joint area, and requires the cross-section of the steel bar to be smooth and flat. At the same time, it consumes a lot of electricity during welding and requires high welding machine power, so it is rarely used.

Flash butt welding refers to the process of spraying molten metal particles from the joint of the steel bar end during welding, presenting sparks (i.e. flash). At the same time as molten metal is sprayed out, oxides and slag inclusions are also carried out, which improves the quality of welded joints and is widely used, especially for the butt joint of low-carbon steel and low alloy steel.

2. The following precautions should be taken when using a butt welding machine:

Adjust the distance between the two jaws. When turning the adjustment screw to make the control lever at the left limit, the distance between the jaws should be the difference between the total extension length and extrusion amount of the two welded parts. When the control lever is at the right limit, the distance between the jaws should be the total extension length of the two welded parts plus 2-3mm, which is the original position before welding.

Adjust the short-circuit limit switch to automatically cut off the power supply when the welding is completed (reaching the predetermined extrusion amount).

Adjust the jaws according to the shape of the weldment, so that both jaws are at the same level, and then clamp the weldment.

To prevent instantaneous overheating of the welded part, the adjustment stages should be increased step by step during the trial welding, and an appropriate secondary voltage should be selected. When flash butt welding, it is advisable to use a higher secondary voltage.

To avoid overheating of components during welding, it is necessary to open the cooling water valve and allow water to flow before welding can be carried out. For the convenience of inspection, there is a funnel on the left front of the welding machine, which can directly observe the water flow situation to check whether there is cooling water flowing inside the welding machine.

3. Key operating points of steel bar butt welding machine

Welding machine operators must undergo professional training, be familiar with the structure, performance, and operating procedures of the welding machine, and master knowledge of process parameter selection, quality inspection standards, and other related knowledge.

Before operation, check whether the various mechanisms of the welding machine are sensitive and reliable, whether the electrical system is safe, whether the cooling water pump system has water leakage, and whether the lubrication parts are well oiled.

It is strictly prohibited to weld steel bars exceeding the specified diameter. The main reinforcement must be welded first and then cold drawn. To ensure welding quality, cleaning, rust removal, and correction work should be carried out within a range of approximately 150mm of the felt end.

When operating, operators must wear colored protective glasses and hats to prevent arc light from irritating the eyes and molten metal from burning the skin.

The welding machine should be parked in a clean, dry, and ventilated area. The welding machine used on site should have a rain proof, moisture-proof, and sun proof machine shed, and be equipped with fire-fighting equipment. Flammable materials should not be piled up within the welding range.

The welding machine should be equipped with a dedicated wiring switch and installed in the switch box. The capacity of the fuse should be 1.5 times the capacity of the machine. The welding machine casing must be well grounded.

After welding, the appearance inspection shows that the steel joint should be properly upset, and there should be no cracks or obvious burns on the surface. The crankshaft of the joint axis shall not exceed 6 °, the deviation shall not exceed 1/10 of the diameter of the steel bar, and shall not exceed 2mm.

After the operation, the site should be cleaned and sparks should be eliminated. In winter, compressed air should be used to blow out the water in the cooling pipeline and cut off the power supply.

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