I want to perform a welding operation inside a progressive die running at approximately 150 strokes per minute. The space to perform the weld is cramped - the smaller the head, the better. What sort of equipment do I need to get this project off the ground? Does your company have any experience in this area?

-- John Barker (john_barker@esproducts.com), January 18, 2002

Answers

John - To begin with, a better understanding of your process and your needs will have to be known. The type of welding that you need, the placement of the weld in with other machinery, the materials that are to be fused, etc. If you would like to discuss this possibility, please call me so we can determine what you need and if it is even possible! Ray Michelena T.J.Snow Co. 423.238.9447

-- Ray Michelena (raymichelena@tjsnow.com), January 21, 2002.

At 150 strokes per minute, it would have to be a very fast weld. The normal weld time for sheet metal varies between 6 and 24 cycles of the 60 cycle AC line. Each weld needs to start after the tip force has stabilized, and should have about half of its weld time as hold time, allowing the nugget to solidify under full weld force. So, 150 welds per minute are possible, if we can keep the tips cool. The duty cycle is very high. This type of duty cycle is tolerated in seam welders with external flood cooling to augment the internal cooling. If the welds can be done in about 6 cycles of heat, and you have really good cooling, such as size 3 caps, probably Cupal material (because it withstands high heat without permanent softening) with flood cooling, you can do it. Make sure there is time for the force to stabilize, and allow for 3 cycles of hold time. If the material is over 0.8MM, it will be hard to weld it that fast.

-- David Bacon (dbacon@updatetechnology.com), April 19, 2002.