Introduction to Flash Welding

[Reference: Welding Process Slides, The Welding Institute]

Basic Steps in Flash Welding

(a)
Electrodes

(c)

Position and Clamp the Parts

Flash

(b)

(d)

Upset and Terminate Current

Apply Flashing Voltage and Start Platen Motion
[Reference: Welding Handbook, Volume 2, p.583, AWS]

Equipment Example of Flash Welding

[Reference: Welding Process Slides, The Welding Institute]

Typical applications: (1) Butt welding of matching sections. (2) Chain links. (3) Railway lines. (4) Window frames. (5) Aero-engine rings. (6) Car wheel rims. (7) Metal strip in rolling mills.

Advantages of Flash Welding

Flexible cross sectioned shapes / Fleksible bentuk penampang melintang Flexible positioning for similar cross section parts/ Fleksibel posisi yang sama untuk bagian penampang melintang Impurities can be removed during upset acts/ Pengotor dapat dihilangkan selama tindakan hantaman Faying surface preparation is not critical except for large parts /Preparasi bidang sambungan tidak penting kecuali untuk bagian yang besar Can weld rings of various cross sections/ Dapat mengelas lingkaran dari berbagai lintas bagian

Narrower heat-affected zones than those of upset welds / Zona yang terkena panas
kecil daripada menghantam/ lasan

Limitations of Flash Welding

Produce unbalance on three-phase primary power lines/ Menghasilkan ketidakseimbangan pada tiga-fase kabel listrik utama The ejected molten metal particles present a fire hazard/ Partikel-partikel terlontar logam cair menimbulkan bahaya kebakaran Require special equipment for removal of flash metal/ Membutuhkan peralatan khusus untuk menghilangkan logam flash/ Difficult alignment for workpieces with small cross sections /Sulit penemepatan bagi benda kerja dengan penampang kecil Require almost identical cross section parts/Memerlukan hampir sama bagian penampang

Common Types of Flash Welds

Axially Aligned Weld
Dies

Fixed Platen

Movable Platen

Cross Section After Welding

Transformer
[Reference: Welding Handbook, Volume 2, p.589, AWS]

Common Types of Flash Welds (CONT.)

Miter Weld

Fixed Platen

Movable Platen

Cross Section After Welding

Transformer

[Reference: Welding Handbook, Volume 2, p.589, AWS]

Common Types of Flash Welds (CONT.)

Ring Weld

Shunt Current

Fixed Platen

Movable Platen

Cross Section After Welding

Transformer
[Reference: Welding Handbook, Volume 2, p.589, AWS]

Typical Mill Forms and Products of Upset Welding

[Reference: Welding Handbook, Volume 2, p.600, AWS]

Systems Electrical Force Application

Savage, Flash Welding, Welding Journal March 1962

Applications
Wheel Truck Rims Ball Bearing Raceways Bar Welding Strip Welding During Continuous Processing Pipelines

Schematic of Typical Flash Weld Cycle

Savage, Flash Welding, Welding Journal March 1962

Factors Which Effect Extent of Stable Stage 2

Material Electrical & Thermal Conductivity Platen Motion During Flashing Initial Clamping Distance Preheat Material Geometry

Electrical & Thermal Conductivity

Instantaneous Temperature

Temperature

HAZ
Burnoff Dist from Instantane ous Inte rface

High Resistance = More I2R Heating Low Thermal Conductivity = Less Heat Out
More Rapid Heating Longer Stage 2 Higher Temperature Wider HAZ