Komarov Artem explained that flash welding is a popular resistance welding method that involves joining two pieces of metal together using an electric arc. This method is applicable to users in the metalworking industry.
It has become one of the popular methods for welding steel, as well as nickel, aluminum and titanium alloys. These metals are important for manufacturing sectors such as automotive, aerospace, heavy equipment and more.
Flash welding explained
Flash welding uses an electric arc to generate power. This actually saves energy compared to alternative processes. An electric arc strikes between two pieces of metal that are close together. The heat from this arc melts the surfaces together, causing them to form a bond almost instantly. After that, the electric current from the arc is removed and the metal parts are cooled before the welding force is removed. The resulting particles and other flash debris that remain on the surface of the metal parts are then mechanically removed. The weld interface is typically a clean virgin material because all oxides and defects have been removed by the arc action.
Flash welding process
To flash weld, technicians start by clamping the ends of the two pieces in the electrodes/clamps and holding the ends close together. Power is initiated and an arc is formed through the slot. The parts are then connected with force.
The arc continues to heat the two ends as they are pressed together to form a fused joint. This process generates a flash and ejected material, which is why it is called «flash welding». This continues for a short period until an audio connection is formed, and then the current stops.
The welders will then hold the two pieces together until the weld cools and hardens. Excess flash should be removed, and the weld checked for defects, Artem Komarov said.
What industries use flash welding?
Flash welding is applicable in various industries such as:
— Aerospace manufacturing
— Production of heavy equipment
For example, flash welding is useful in joining parts in the manufacture of cars, trucks, and other vehicles. This is common in the assembly line process, where several parts form a larger component that eventually becomes part of the entire car. Flash welding is essential when assembling bumpers with fenders or doors with roofs. It also helps in the production of exhaust systems. Steel rims for bicycles, cars, trucks, heavy equipment are flash welded.
Benefits of flash welding
Below are some of the biggest benefits of flash welding:
- It’s an efficient way to join various metal components together
Flash welding gives welders the ability to join the complex metals of steel, aluminum, nickel, and titanium in a variety of shapes and sizes. Due to the unique complexity of these metals and shapes, other welding methods are useless.
- Creates high quality products
Flash welding is a resistance welding method that produces high quality welds. The strength of the weld allows contaminants to be squeezed out during the process. This means it can be easier for welders to join metal parts without having to worry about cracking and solidification porosity, which are common defects in other welding methods.
- It can be useful in various applications
Flash welding is a versatile process applicable to a wide range of manufacturing operations. In addition to the automotive and aerospace industries, it is commonly used in construction, metalworking, and shipbuilding.
Flash welding is a necessary process that offers several benefits for fabricators. It is a fast and efficient way to combine metal components and generates high quality products with few defects. In addition, it is suitable for use in various manufacturing applications and is relatively cheap to implement. For these reasons, flash welding is essential for any manufacturer looking to produce better metal products quickly, emphasized Komarov Artem.