High Power Pulsating Flash Butt Welding Machine

Characteristics of High-power Pulsating Flash Butt Welder:

The equipment is used for butt welding of large cross-section steel plates. The materials that can be welded include stainless steel, carbon steel, high-speed steel, etc. The maximum cross-sectional area is 20,000 square millimeters.

The welding is firm, with no slag inclusions or pores on the surface of the weld joint, achieving a sealing effect. The equipment is equipped with an inert gas protection function.

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The Principle of High-power Flash Butt Welding Machine

The ends of the two workpieces are clamped by two clamp electrodes and connected to the power supply (transformer), and the movable fixture moves forward. When the end faces of the two welded pieces start to come into contact, electricity is applied for heating. The contact point forms liquid metal due to heating and explodes, generating a spark jet and creating a flash.

When the flash occurs, the two end faces of the welded part are heated. When the welding temperature is reached, the moving fixture suddenly accelerates and exerts a huge forging force to squeeze the two end faces against each other, causing intense plastic deformation in the welding area. While extruding and melting the metal, interactive crystals form on the bonding surface, thus forming a firm welded joint.

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Welding Samples
Equipment Parameter

Name	High-power Pulsating Flash Butt Welding Machine
Power supply category	AC
Model	AUNS-Y02-800
Rated voltage	380V 3Ph 50HZ
Transformer capacity	800KVA
Transformer insulation class	F
Primary current	2000A
Maximum short-circuit current	70KA
Equipment structure	Direct pressure structure
Pressurization method	Hydraulic pressurization
Demand for cooling water flow	80L/min

Machine Structure Description:

Rack

Box-type vertical structure, heavy-duty reinforced fuselage. It is made by laser cutting, CNC bending, welding, grinding, sandblasting and baking varnish processing of high-quality steel plates. The overall structure is analyzed by force simulation with professional software to ensure the rigidity and precision requirements of the workpiece during welding.

Pressurization Mechanism for Moving And Static Electrode Seats

It adopts a hydraulic pressurization form and a vertical pressurization mechanism. The main shaft is hardened by surface quenching and ground, featuring high guiding accuracy, high rigidity and wear resistance, ensuring the reliability when clamping parts.

Sintering And Top Forging Mechanism

The servo electro-hydraulic proportional valve is adopted to control the hydraulic cylinder to achieve the control of the flash and top forging processes of the workpiece. The flash distance, flash speed, top forging distance, etc. can be set.

Welding Transformer

It is made of high-permeability silicon steel sheets and cast with epoxy resin. The transformer adopts an internal circulation water-cooled structure to ensure that the welded transformer does not experience significant temperature rise due to long-term operation, preventing welding spatter from entering the transformer’s interior and extending the transformer’s service life.

Welding Control System:

The control and operation adopt a new type of welding controller, which can store multiple sets of welding parameters. Secondary circuit sampling is adopted to ensure the accuracy of the welding current within the effective working range. It can achieve complex welding processes such as preheating, flash butt welding and tempering. It can display the welding current and welding time, and has functions such as current over-limit alarm. The human-machine interface is easy to operate. All set parameters are clear at a glance, and the working status can be displayed on the LCD screen. With multiple power mode options, it can be combined with various welding processes to meet the requirements of various welding techniques.