Comprehensive Guide To Welding Machine Selection, From Selection To Operation, One-stop Guide

In industrial production, welding machines are key connecting equipment, and their selection and operation directly affect the quality and production efficiency of products. This article will provide you with a comprehensive guide for selecting and operating welding machines, helping you better understand how to choose the appropriate welding machine and how to perform efficient and safe operations.

1.Types and application scenarios of welding machines

There are many types of welding machines, each with its unique purpose and advantages. Understanding these different types of welding machines and their application scenarios can help you choose the equipment that best suits your needs. The following are several common types of welding machines and their application scenarios:

Spot Welding Machine:

Characteristics: The spot welding machine applies pressure on the contact surface of the workpiece through two electrodes, and locally melts the contact point to form a welding point through instantaneous high current.

Application scenario: Mainly used for welding thin metal plates, such as body welding in automobile manufacturing, welding of household appliance shells, etc. This welding method has fast speed, high weld strength, and is suitable for large-scale production.

Seam Welding Machine:

Features: The seam welding machine is similar to a spot welding machine, but its electrode is a roller, which can achieve continuous welding. The shape of the weld seam is controllable and the welding process is stable.

Application scenario: Suitable for occasions that require continuous welding, such as oil drums, steel pipes, and other products with high sealing requirements. Seam welding can ensure uninterrupted welding, improve sealing performance and structural strength.

Laser Welding Machine:

Features: Laser welding machines use high-energy density laser beams as heat sources to achieve high-precision and high-speed welding. Suitable for various metallic and partially non-metallic materials.

Application scenarios: Widely used in electronic components, precision machinery, aerospace and other fields. Laser welding has high precision, small heat affected zone, and is suitable for welding complex structural components and high requirements.

Arc Welding Machine:

Characteristics: The arc welding machine melts the welding material and workpiece through the high temperature generated by the arc, forming a welding joint. According to different welding processes, it can be divided into manual arc welding, gas shielded welding, etc.

Application scenarios: Widely used in fields such as building steel structures, mechanical manufacturing, pipeline welding, etc. Arc welding technology is mature, widely applicable, and relatively simple to operate.

Resistance Welding Machine:

Characteristics: The resistance welding machine applies pressure to the workpiece through electrodes, while generating heat through the current flowing through the workpiece, causing the contact surface to melt and form a welding joint.

Application scenario: Suitable for welding plates and pipes, such as automotive manufacturing, home appliance production, etc. Resistance welding has fast welding speed, high efficiency, and is suitable for large-scale production.

2.Key factors in selecting welding machines

Understanding your specific needs and application scenarios is crucial when choosing a welding machine. The following key factors need to be considered:

(1) Material type: Different materials require different types of welding machines.

For steel: Suitable for using arc welding machines (such as MIG/MAG welding machines) and spot welding machines.

Aluminum alloy: Due to its high thermal conductivity, pulse welding machines or laser welding machines are commonly used.

Stainless steel: TIG welding (tungsten inert gas welding) or laser welding can be used as they require high-quality welds.

Metal types: Different metal materials require different welding machines. For example:

Non metallic materials, such as plastic, require specialized plastic welding machines.

(2) Welding thickness: The power and performance of the welding machine should match the thickness of the material. Excessive power may burn through the material, while insufficient power may prevent effective welding.

Such as plasma arc welding machine: used for welding high demand thick plates.

TIG welding machine: suitable for welding medium and thick plates that require high-quality welds.

Spot welding machine: suitable for rapid welding of thin plates, such as body welding in automobile manufacturing.

Laser welding machine: High precision, suitable for precision welding.

Thin plate (0.5-3mm)

Medium thick plate (3-12mm)

Thick plate (>12mm)

(3) Welding speed:

Laser welding machine: With fast welding speed, it is suitable for high-precision and large-scale production.

Seam welding machine: used for continuous welding, fast speed, suitable for manufacturing tanks, pipelines, etc.

MIG/MAG welding machine: With fast welding speed, it is suitable for welding medium thick plates in mass production.

For large-scale production, high welding speed is key. When choosing a welding machine, it is important to consider whether its welding speed can meet production requirements

Welding quality requirements: Depending on the purpose of the welded parts, the requirements for welding quality also vary. For general industrial welding, MIG/MAG welding machines and spot welding machines are usually sufficient.

3.Basic steps and precautions for welding machine operation

(1) Equipment inspection: Before operation, it is necessary to check whether the welding machine is normal, and whether the power supply, gas source, cooling system, etc. are well connected.

(2) Material preparation: Clean the welding area to ensure no oil stains or rust to ensure welding quality.

(3) Set parameters: Set welding current, voltage, time, and other parameters according to material and process requirements.

(4) Safety protection: Wear protective goggles, gloves, etc. to ensure safe operation.

(5) Practical operation: Weld according to the set parameters, maintain uniform speed and stable welding gun position.

(6) Inspection and repair: After welding is completed, check the quality of the weld seam and promptly repair any defects.

4.Common welding problems and solutions of welding machines

Common problems with welding machines

(1) Welding spatter: Due to excessive current or unclean materials, it may be necessary to adjust the current or clean the materials.

(2) Welding deformation: may be caused by excessive heat input, and welding speed and heat input need to be controlled.

(3) Weld cracking: It may be due to high carbon content in the material or too fast cooling rate, requiring adjustment of the welding process or preheating of the material.

Maintenance and upkeep of welding machines

(1) Regular inspection: Regularly inspect the various components of the welding machine, such as cables, welding guns, etc., to ensure that there is no damage.

(2) Cleaning and maintenance: Keep the equipment clean, especially the connection between the welding gun and the grounding wire.

(3) Lubrication: Regularly lubricate the parts that require lubrication to ensure the normal operation of the mechanical components.

(4) Calibration: Regularly calibrate welding parameters to ensure consistency in welding quality.

Through the introduction of the above aspects, we hope to help you better understand the selection and operation of welding machines, and improve welding efficiency and quality. If you have any further questions, please feel free to contact PDKJ and we will be happy to serve you.