Capacitor welding - welding method, so-called stored energy. Energy charges are accumulated in the capacitors during charging from the rectifier and transformed into heat. It, in turn, is formed in contact at the instants of current flow between the contacting blanks. Accordingly, the capacitor welding is often called a contact.
Content
Distinguishing features of the welding capacitor
The main difference between this welding technology is environmentally friendly and speed. Standard capacitor welding apparatus operates at high currents. To provide the highest quality joint with a small expenditure of electrical energy.
Generally capacitor welding, exactly how and equipment for this purpose, is used in cases where you want microwelding or welding large cross sections and thicknesses. The principle of operation is as follows:
- Accumulates enough energy in capacitors.
- The charges are converted into heat used for welding.
We can talk about absolute environmentally friendly, since condenser welding, even a homemade, actually does not affect the environment. The aggregates do not require coolant due to zero heat generation. This unconditional plus allows you to increase the life cycle of the entire welding machine.
Instead of standard cylinders, optional servo drives are embedded in the car, which reduces the need for the so-called pneumatic connection. Integrated elements allow you to quickly and efficiently scap the welding force. In this case, the electrodes act on the surface extremely delicately.
So, we list the advantages of condenser welding:
- high welding speed;
- welding accuracy;
- environmental friendliness;
- clutch reliability;
- durability of welding equipment.
Condenser welding due to high accuracy does not deform, does not smear the metal. The aggregates are gentle by various kinds processed sputtering and coatings. High quality indicators are demonstrated in the contact or shock method. For example, shock-condenser welding copes perfectly when processing non-ferrous metals and alloys based on them.
Conclusion: seam is obtained neat, durable, welding takes the minimum time.
Varieties of welding
Select four types:
- electromagnetic;
- rechargeable;
- condenser;
- inertial.
Condensatory was widely used in industry due to the totality of operational characteristics. The optimally technological phenomenon, during which the delicate contact of metal elements is carried out due to heat dissipation. Moreover, dirt, oxide films, additional inclusions, irregularities are eliminated from the welding zone by compressive effort. As a result, interatomic compounds between the treated coatings are formed.
Energy charges accumulate in the process of charging from the generator or rectifier. You can adjust the energy using a voltage change and charging capacity.
Types of condenser welding:
1. Bestranformator.
Capacitors discharge the energy to the surface being processed. Admission two charging schemes:
- 1000 μF capacitors accumulate energy to voltage up to 1000 V by means of an increaseing transformer; welding time is 0.005 s; Welding current in the range from 10 to 100 A. Technology is dangerous for a person due to high voltage;
- 40-400 thousand μF capacitors accumulate energy to 60 V by a lowering transformer; The welding time reaches 0.6 s; Welding current in the range from 1000 to 2000 A.
2. Transformer.
The capacitor discharges the energy charge on the primary winding of the transformer device. Moreover, the billets are located in the so-called welding circuit, which is connected to the secondary transformer winding. This type of welding is operated as a micro welding with characteristics:
- charging voltage - 1000 V;
- welding time - 0.001 s;
- welding current - 6000 A;
- capacitance capacitors - 1000 μF.
Scheme of condenser transformer welding
The capacitor accumulates energy to a certain amount at the left position of the lever. At the right, the category of heat exchangers on the primary winding of the transformer is performed. Condenser welding, as the scheme demonstrates, E.D.S. is induced in the secondary winding. It in turn causes current strength in the welding chain.
Advantages of condenser welding
1. High speed and density of welding current.
This contributes to highly concentrated heat dissipation in the compound areas. Provides instant melting of a small section of metal products. As a result, seam does not need additional processing. A specialist gets the ability to weld alloys and metals, excellent in its thermophysical parameters.
2. Efficiency and stability of work.
Each welding cycle requires a constant, clearly verified volume of electrical energy. It provides high stability and welding efficiency.
3. Practicality.
Due to the speed and pause, the point capacitor welding is available in the air cooler system of the electrodes. The work is effectively automated and mechanized.
4. Low power consumption.
The required power is from 0.05 to 20 kVA. Low energy is explained by the gradual selection of power from the network with the stabilization process.
5. Delicacy of welding.
Dosing energy dosage. In the area of \u200b\u200bcontact, there is a solid seam of a small thickness. This feature is used in delicate welding of non-ferrous metals.
Scope of application of condenser welding
This welding technology is used:
1. To connect a homogeneous type metals:
- steel of all classes;
- brass harves;
- billets from aluminum alloys;
- billets of refractory metals;
- blets from bronze and others.
2. For welding of thick plates to thin, as well as welding of heterogeneous metal:
- bronze and silver;
- brass and nichrome;
- constanta and stainless steel;
- constanta and low carbon steel.
Bestrazing Formator Method used:
- for docking spirals of small diameter;
- to connect the so-called thermocouple;
- for butt welding of incandescent threads.
BestranFormator welding is most often used in the production of hours and other products that have microdetal.
The transformer method is used in production:
- cathodes pool;
- spirals for incandescent lamps;
- sylphons;
- metal toys;
- relay;
- membranes;
- multi-layer bags of copper foil;
- microcircuits.
Point microvel with ease connects parts from copper and other non-ferrous metals. It is welding copper wire, and a mix of thin and thick plates of bronze and silver, and docking miniature parts.
Colored Metal Welding Technology
In physical and chemical and technological data, non-ferrous metals contrast with traditional steel. Depending on the metal, experts use various methods of thermal processing. We highlight the features of non-ferrous metal welding:
- melting temperature;
- boiling temperature;
- density;
- affinity for atmospheric gases;
- mechanical data at low and high temperatures.
Metals are distinguished from the set of data:
1. Heavy colored (silver, platinum, copper).
2. refractory and active (tungsten, zirconium, titanium, molybdenum).
3. Light (beryllium, magnesium, aluminum).
With the exception of precious metals, from the first group are melted by all modern methods of welding of copper alloys. Machine mechanized devices are most often used for welding copper wires. They provide high quality and compliance with the original sizes.
As for metals of the second and third group, units with high concentration of energy are required for processing. It is not recommended to welcome details from this category in view of the formation of volatile harmful compounds.
Welding copper wire with your own hands
Alone, quite bye, assemble the device for welding copper wire. To do this, you will need a transformer 450 W, as well as several reducing components.
The transformer is standard, with a primary winding with copper 2x0.75 mm thick and a secondary winding of a 6-millimeter aluminum power cable. Directly for welding work, a coal electrode is required for copper welding.
The device for welding copper wires functions on alternating current from 30 to 40 A.. At the same time, the highest voltage point can be 15.5 V. In the role of the electrode handle, two clamps of the "crocodile" type are perfect. A coal electrode produced from the trolleybus contact brush can be used as a conductor for a self-made unit.
What is curious, such an invention, in the case of neat operation and storage will serve not one year. Make sure that the battery does not discharge, as well as behind the contacts. Copper Wire Welding Scheme does not involve the use of high-resource devices. Even the homemade apparatus will perfectly cope with large volumes of work with proper approach and leaning.
Welding machines collected by their own hands can be intended for much more serious purposes. Consequently, the configuration of the machines will differ from mobile to massive. At home, the optimal option will be the desktop versions. They are effectively used to melting light black and non-ferrous metals.
