The welding principle is quite simple. The welding machine, whatever its type and size - applies heat to the two metal pieces that are to be joined.
1. Flash Butt welding for heavy duty applications:The welding principle is quite simple. The welding machine, whatever its type and size -applies heat to the two metal pieces that are to be joined. This heat causes the twometal pieces to melt slightly to form a liquid. A filler material made from tungsten or ametal alloy is often used as a filler material between the two pieces. When the heatfrom the welding machine is withdrawn, the liquefied metal and filler quickly solidify tojoin the two units.Flash butt welding is an advanced and innovative technique for joining mild steel, alloysteel and other dissimilar metals in various tubular or solid forms. Flash butt weldingmay be described as a technique for joining segments of metal rail or pipe in whichsegments aligned end to end are electronically charged, producing an electric arc thatmelts and welds the ends of the segments resulting in a remarkably firm and smoothjoint.When two wires, which are charged with electricity, are made to contact with eachother, they crackle with sparks. The flash-butt welding is a welding method whichharnesses this heat of which sparks generate, to melt and to weld metals.The striking feature of flash butt welding is the resultant weld quality is similar to theparent metal. No additional tools like rods or gas is required and that makes flash buttwelding highly economical. Other important features of flash butt welding include - noelaborate preparation, high accuracy of welded joints and high consistency of weldparameters.Generally speaking, there are three basic types of butt-welding and you adopt one orthe other depending on the thickness of the metals to be joined. For thin metal sheetsor plastic, you can choose a square weld joint. In such cases, the edges of the metalsform 90-degree angles to one another and can be butted together with ease. This is themost economical and common type of butt-welding joint.When you weld thicker materials, the edges must be beveled to form either a single ordouble V-groove. A single V-groove is meant for metal pieces of moderate thicknessincluding almost all varieties of pipes. Filler is usually placed on the wider part of the V-groove to provide firmness to the weld. As regards a double V-groove, both the top andbottom of each object is beveled. Filler is placed on both sides and heated in alternatingpatterns to achieve the most secure weld possible. This double V-shape is more meantfor extra thick or large pieces.Butt-welding is widely used in a wide variety of manufacturing industries, atconstruction sites and in specialty welding shops. Applications include wheels,
2. aerospace, structural members, rings, rods, stationary rail application, anodes, bandsetc.There are available in the market Flash Butt welding machines for many applicationsfrom the smallest to the largest. There are also welders specially designed for heavyduty applications where repeatability in performance is the key. The manufacturers alsosupply necessary tooling and clamping devices for adapting these machines for theproduction of railway shackles, automotive parts, starter ring-gears, wheel rims, chainlinks and assembly of parts by links etc.Source: http://www.everlastgenerators.com