Butt Welding Machine

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Our Products include Spot Welders, Butt Welders, Flash Butt Welders, Seam Welders, Medium Frequency Inverter DC Welders, Single-phase/Three-phase Secondary Rectifier Spot Welder, Wire Mesh Welding Machines, Sink Producing Line, Automatic Argon Arc Seam Welding Machines, High/Ultrasonic/Medium Frequency Induction Heating Machines, and other automatic equipment.

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What is Butt Welding Machine

The butt welding machine is used for welding 40-2800 mm diameters of HDPE – PP – PVDF pipes and fittings up to 4-32 Bar. It provides powerful, easy and serial welding with the shortest set-up operation in accordance with ISO 12176 – 1 international standard. Butt welding offer ease of usage with their lightweight construction. The maximum working pressure of the machines is designed as 150 Bar and they are suitable for operation at -10 C ° ~ + 40 C ° ambient temperature.

Benefits of Butt Welding Machine

Energy saving
The radiator flash butt welding machine uses two 125KVA welding resistance transformers as the power source, pneumatic pressing, upsetting, and no hydraulic station. Compared with other single-phase AC welding resistance transformers using two 315KVA And two welding machines with a power of 18KVA hydraulic station, UN-250AB welding machine can save electricity up to 78℅.

Low requirements for power grid
Only 250KVA power grid can be satisfied.

High welding precision
Using programmable controller PLC and imported stepping motor to control the flashing process, the burning amount and burning speed can be accurately set; the welding current is controlled by the microcomputer welding resistance controller. The center distance error of the film head after welding It can be controlled within ±0.2mm, which is convenient for subsequent assembly and welding.

Automatic centering function
Ensure that the distance between the two ends of the pipe column and the two ends of the piece is the same before welding, so as to ensure the same amount of burning at both ends.

High welding efficiency
Since the workpiece is pressed by the double force cylinder, its reaction speed is significantly faster than that of the hydraulic cylinder.

Convenient operation and maintenance services
Since there is no hydraulic station, the product has fewer debugging points and fault points, and there will be no oil leakage.

Inverter Copper Aluminum Pipe Butt Welder

Application of Butt Welding Machine

Applications in manufacturing

Butt welding machines are widely used in the manufacturing industry and can be used to produce various machinery and equipment, auto parts, ship components, etc. The fast, efficient and high-quality welding capabilities of the butt welding machine can meet the high requirements for welding processes in the manufacturing industry.

Applications in the construction industry

Butt welding machines are also widely used in the construction industry and can be used to weld various building steel structures, drainage pipes, plumbing pipes, etc. Butt welding machines can meet the high requirements in construction projects, ensure welding strength and quality, and improve the efficiency of construction work.

Applications in other industries

In addition to manufacturing and construction, butt welding machines are also widely used in other industries, such as aviation, electric power, petroleum and other fields. Butt welding machines can be used to produce various mechanical equipment, electrical equipment, pipelines, etc. to ensure high welding quality and strength and meet the welding process requirements of various industries.

Types of Butt Welding Machine

Copper Aluminum Pipe Butt Welder
UN3 Series Copper and Aluminum Tube Butt welding Machines specially designed for Copper Tube and Aluminum Tube welding, it can replace the High-voltage Flash Welding Machine and brazing machine with lower and old technology.

Air Conditioning Pipe Butt Welder
Air Conditioning Pipe Butt Welder also called UN3 Series Copper and Aluminum Pipe Butt welding Machines specially designed for Copper Pipe and Aluminum Pipe welding, it can replace the High-voltage Flash Welding Machine and brazing machine with lower and old technology.

Compressor Pipe Butt Welder
Compressor Pipe Butt Welder also called UN3 Series Copper and Aluminum Pipe Butt welding Machines specially designed for Copper Pipe and Aluminum Pipe welding, it can replace the High-voltage Flash Welding Machine and brazing machine with lower and old technology.

Refrigerator Condenser Butt Welding Machine
Refrigerator Condenser Butt Welding Machinealso called UN3 Series Copper and Aluminum Pipe Butt welding Machines specially designed for Copper Pipe and Aluminum Pipe welding, it can replace the High-voltage Flash Welding Machine and brazing machine with lower and old technology.

Components of Butt Welding Machine

Butt welding machine frame and guide rails
The frame houses all important parts of the butt welder. The frame is made of high-quality steel plates that are stress-relieved and welded, and has good load-bearing capacity and rigidity. Guide rails are used to ensure safe and reliable movement of the moving plate and facilitate the feeding of welding parts.

Butt welding machine feeding mechanism

The function of the feeding structure is to make the weldment follower plate move and ensure the required upsetting force.

Butt welding machine clamping mechanism
The clamping mechanism consists of two clamps, one is stable, called the stable clamp, and the other is movable, called the moving clamp. The stable clamp is installed directly on the frame, and the movable clamp is installed on the moving plate and can move left and right with the moving plate. The welding fixture consists of a column, a transmission mechanism, an upper and lower fixture, a flux cylinder, etc. It is equipped with a monitor, control switch, secondary voltmeter, buzzer (time display), etc. The diameter of the flux cylinder should be adapted to the diameter of the welding steel bar, and the accessories on the display (such as voltmeter, time display, etc.) should be fully equipped.

Butt welding machine main circuit and control unit
The main circuit of the butt welding machine includes fuses, resistors, thyristors, capacitors and welding resistance transformers. The control unit consists of a microcomputer control system, a trigger circuit and a welding start switch. It consists of a photoelectrically isolated input and output interface, a synchronous detection circuit, a digital dial input interface, and a luminous indication output interface. The controller has simple structure, stable operation, reliable performance and easy maintenance.

How to Choose Butt Welding Machine

Power
The power supply power of a butt welding machine is usually 150W to 500W. The greater the power, the wider the range of application scenarios, but the price will also increase accordingly.

Voltage
When selecting a butt welding machine, you need to select the appropriate voltage value based on actual needs. Usually the voltage range is between 110V and 220V, and the voltage needs to be selected according to the power supply conditions of the workplace.

Welding current
The welding current of a butt welding machine is usually between 20A and 200A, and the current range used in general factories is more than 50A.

Welding speed
The welding speed of a butt welding machine refers to the welding length that can be completed per minute. The welding speed needs to be considered based on the specific use occasion.

Other parameters
In addition to the above four parameters, there are some other parameters that need to be considered, such as current control, overload protection, automatic shutdown protection, electronic start, etc.

Butt welding machine operation steps

Preparation before welding
Clean the oil circuit joints and connect all parts of the welding machine correctly.Measure the power supply voltage and confirm that the voltage meets the requirements of the welding machine.Check and clean the heating plate (when the coating is damaged, the heating plate should be replaced, the surface of the heating plate; the polyethylene residue on the surface of the heating plate can only be removed with wooden tools, and the oil and grease must be treated with clean cotton cloth and alcohol).According to the welding process, set the parameters such as heat absorption, cooling time and heating plate temperature. The heating plate should be properly preheated at the welding temperature before welding to ensure that the temperature of the heating plate is uniform.

Clamping pipe components
Use a roller or bracket to level up the tube, adjust the concentricity, use a clamp to correct the out-of-roundness, and leave enough welding distance.

Milling welding surface
Milling is thick enough to make the welding end face smooth, parallel to ensure that the gap between the butt end faces is less than 0.3mm, and the amount of misalignment is less than 105 of the wall thickness of the weld. It must be milled again when re-fixing.

Dragging pressure measurement and inspection
The drag pressure (Pt) must be measured and recorded each time during welding.

Heating
Set the heating plate, adjust the welding pressure (P1) = drag pressure (Pt) + welding specified pressure (P2).When the height of the circumferential crimping protrusions at the welding on both sides of the heating plate reaches the specified value, the pressure is reduced to the drag pressure (Pt) or under the condition that the heating plate and the welding end face are in close contact, the endothermic timing is started.

Switch docking
Draw out the heating plate within the specified time, immediately fit the welding surface, and quickly increase the pressure to the welding pressure (P1) at a uniform rate, and high-pressure collision is strictly prohibited.

How to Maintain Butt Welding Machine

Lubrication

Ensure that all moving parts, such as clamping mechanisms and welding head components, are properly lubricated. Lubrication reduces friction and wear, promoting smooth operation and preventing premature component failure.

Inspection of Electrical Components

Regularly inspect electrical components, such as cables, connectors, and switches, for signs of wear or damage. Faulty electrical connections can lead to inconsistent weld performance or pose safety hazards.

Cooling System Maintenance

Maintain the cooling system by cleaning or replacing filters, checking coolant levels, and ensuring proper circulation. A well-maintained cooling system prevents overheating and prolongs the life of welding machine components.

Calibration and Alignment

Periodically calibrate and align the butt welding machine to ensure accurate electrode positioning and welding parameter settings. Proper calibration contributes to precise weld bead formation and consistent welding results.

Safety Check

Conduct routine safety checks on emergency stop buttons, interlocks, and protective guards. Ensuring that safety features are functional helps prevent accidents and promotes a safe working environment.

Electrode Inspection and Replacement

Inspect the welding electrode regularly for signs of wear, deformation, or damage. Replace worn or damaged electrodes promptly to maintain optimal weld quality.

Training and Operator Awareness

Provide training to machine operators on proper machine operation and maintenance procedures. Operator awareness of maintenance requirements ensures that the machine is cared for correctly during daily use.

Record-Keeping

Maintain a comprehensive record of maintenance activities, including cleaning schedules, lubrication intervals, and calibration dates. This record-keeping helps track machine performance and supports timely maintenance planning.

Our Product

GUANGZHOU DRAGON WELDING CO., LIMITED is a professional automatic welding equipment manufacturer, which specializes in designing, producing, sale and service together.Our Products include Spot Welders, Butt Welders, Flash Butt Welders, Seam Welders, Medium Frequency Inverter DC Welders, Single-phase/Three-phase Secondary Rectifier Spot Welder, Wire Mesh Welding Machines, Sink Producing Line, Automatic Argon Arc Seam Welding Machines, High/Ultrasonic/Medium Frequency Induction Heating Machines, and other automatic equipment.Main applied to metal welding of Automobile Parts Manufacturing, Aerospace and Aviation Parts, Road and bridge construction, Electrical Appliance, Hardware Manufacturing, Pressure Vessel, Battery, Refrigeration Industries, and so on.

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FAQ

Q: What does 135 mean in welding?

A: Depending on the type of shielding gas being used, there are further sub-classifications into metal inert gas welding (MIG), process no. 131, when an inert gas is used and metal active gas welding (MAG), process no. 135, when an active gas is used.

Q: What is the hardest position in welding?

A: The overhead position weld is the most difficult position to work in. The welding will be performed with the two pieces of metal above the welder, and the welder will have to angle him or herself and the equipment to reach the joints. One major issue can be the metal sagging from the plate.

Q: What is the strongest welding technique?

A: TIG welding
What Type Of Weld Is The Strongest? TIG welding is often considered the strongest weld since it produces extreme heat, and the slow cooling rate results in high tensile strength and ductility. MIG is also an excellent candidate for the strongest type of weld because it can create a strong joint.

Q: What is A and Z in welding?

A: ISO 2553 is a welding symbol standard used in many parts of the world and it specifically permits the engineer to specify fillet welds based on leg, throat or both. Sizes prefixed with "z" refer to leg length while the "a" prefix refers to effective throat dimension.

Q: What does 5G mean in welding?

A: In the 5G position, the pipe is fixed at one or both ends and the welding operator must travel in one of two directions, either vertical-up or vertical-down. Depending on the location of the pipe, the application may also require welding either overhead or in a flat position.

Q: What is the hardest weld to master?

A: TIG welding
TIG welding is the hardest form of welding to learn for a variety of reasons. The process of TIG welding is slow and takes time to get used to as a beginner. A TIG welder requires a foot pedal to feed the electrode and control the variable amperage while maintaining a steady hand at the welding torch.

Q: What is flashbutt welding?

A: Flash (butt) welding is an electrical resistance welding processes used for joining components, where the energy transfer is provided primarily by the resistance heat from the parts themselves. The components are positioned end-to-end across the full joint area.Dear All, Please refer the following detail, and advise how to achieve the FULL PENETRATION BUTT WELD, I would like to have the fabrication drawings with required bevel. FPBW DETAIL.JPG.

Q: What is the purpose of flash welding?

A: As with butt welding, flash welding is a method in which the ends of the workpiece are pressed together and welded. It is used for welding thicker workpieces such as heavy anchor chain, rails and pipes. The process is most often used for welding of steel but also for nickel, aluminium and titanium alloys.

Q: What is the hardest type of welding?

A: Tungsten Inert Gas (TIG) welding is widely considered the most challenging welding process to learn. The sheer complexity of the technique requires more practice and focus to master than other less-technical welding methods. TIG welding also results in some of the strongest and sturdiest welds in the industry.

Q: What is the easiest welding to learn?

A: MIG
MIG (metal inert gas) welding is an excellent choice for beginning welders. This easy-to-handle machine is usually spool-fed to create professional-looking joints on both thick and thin metals. MIG welding requires separate shielding gas but doesn't require chipping and cleaning slag as the stick welding process can.

Q: What metal can't be welded?

A: Some examples of material combinations that cannot be fusion welded successfully are aluminum and steel (carbon or stainless steel), aluminum and copper, and titanium and steel. Nothing can be done to alter their metallurgical properties.

Q: Do you push or pull when welding?

A: Material Thickness: For thicker materials, the push technique might be preferred due to its better penetration, while the pull technique is often suitable for thinner materials to avoid excessive heat input. Joint Design: Certain joint configurations might favor one technique over the other.

Q: What is the most difficult weld to make?

Q: What is the main limitation of a spot welding?

A: Limitations of Spot Welding
Not suitable for all metals: Spot welding also won't work with some metal materials, mainly those where a current cannot be passed through. Possible warping: In some cases, spot welding may cause warping or distortion to the metal due to its intense heat

Q: What are the rules for spot welding?

A: Ensure the spot welder has cooled before making any adjustments. Avoid prolonged use, as this can cause heat to build up in the electrodes and arms. When holding work, be aware of the heat created during welding process. Ensure work return earth cables make firm contact to provide a good electrical connection.

Q: How do I choose a spot welder?

A: Range of Material Thickness: The spot welder you choose should be capable of handling the range of material thicknesses you plan to work with. Thinner materials require less welding current and pressure to avoid burn-through, while thicker materials need higher current and pressure to ensure proper weld penetration.

Q: What are the basics of spot welding?

A: Spot Welding machines use a method called resistance spot welding to join overlapping metals between two electrodes using electrical resistance. Squeezing the workpieces between the electrodes applies pressure, and the passage of welding current through the resistive metals generates heat.

Q: Can you weld the same spot twice?

A: Materials such as mild, low carbon and carbon-manganese steels, are considered to be very tolerant to heat input and may accept at least two or more re-weld operations. In the case of low alloy steels, re-welds will be governed by the heat-treated condition in which they were supplied.

Q: Do you need a welding mask with a spot welder?

A: When you are operating a spot welding machine, there is not a very bright arc like what is present when arc welding. So the eye protection recommended is usually no greater than a Shade 5 lens.Is Spot Welding Hard? No, spot welding is not hard, it is relatively simple as long as the process is followed correctly. While this is true for low-carbon steels, high-carbon steels can be harder to weld due to their low resistance, requiring more current to heat up the workpieces.

Q: What thickness metal is spot welding ideal for?

A: 0.20”-0.90” thick
Spot weldments are best when welding material 0.20”-0.90” thick. Materials thicker than 0.90” aren't suitable for a spot weld because the weldment won't be strong enough, and welding can

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