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.
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Flash Butt welding for heavy duty applications
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 two metal pieces to melt slightly to form a liquid. A filler material made from tungsten or a metal alloy is often used as a filler material between the two pieces. When the heat from the welding machine is withdrawn, the liquefied metal and filler quickly solidify to join the two units.Flash butt welding is an advanced and innovative technique for joining mild steel, alloy steel and other dissimilar metals in various tubular or solid forms. Flash butt welding may be described as a technique for joining segments of metal rail or pipe in which segments aligned end to end are electronically charged, producing an electric arc that melts and welds the ends of the segments resulting in a remarkably firm and smooth joint.When two wires, which are charged with electricity, are made to contact with each other, they crackle with sparks. The flash-butt welding is a welding method which harnesses 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 the parent metal. No additional tools like rods or gas is required and that makes flash butt welding highly economical. Other important features of flash butt welding include - no elaborate preparation, high accuracy of welded joints and high consistency of weld parameters.
Generally speaking, there are three basic types of butt-welding and you adopt one or the other depending on the thickness of the metals to be joined. For thin metal sheets or plastic, you can choose a square weld joint. In such cases, the edges of the metals form 90-degree angles to one another and can be butted together with ease. This is the most economical and common type of butt-welding joint.
When you weld thicker materials, the edges must be beveled to form either a single or double V-groove. A single V-groove is meant for metal pieces of moderate thickness including 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 and bottom of each object is beveled. Filler is placed on both sides and heated in alternating patterns to achieve the most secure weld possible. This double V-shape is more meant for extra thick or large pieces.
Butt-welding is widely used in a wide variety of manufacturing industries, at construction sites and in specialty welding shops. Applications include wheels, aerospace, structural members, rings, rods, stationary rail application, anodes, bands etc.
There are available in the market Flash Butt welding machines for many applications from the smallest to the largest. There are also welders specially designed for heavy duty applications where repeatability in performance is the key. The manufacturers also supply necessary tooling and clamping devices for adapting these machines for the production of railway shackles, automotive parts, starter ring-gears, wheel rims, chain links and assembly of parts by links etc.Source: http://www.everlastgenerators.com