Welding is a very important link in the manufacturing industry, and spot welding, as one of the most common welding processes, has been widely used in various fields. The traditional spot welding process uses the principle of resistance heating to apply high-intensity current and pressure to the metal plate at two electrodes, so that the contact parts heat up and melt, and then cool to form a solder joint.
In recent years, ultrasonic metal spot welding technology has been continuously improved and promoted. It converts high-frequency electric energy into ultrasonic vibration, and then transmits the vibration to the metal workpiece to form a plastic flow state on the metal surface in a short time to form a welding connection. This article will make an in-depth comparison of these two processes, analyze their advantages and disadvantages and applicable scenarios, so as to help you better understand these two welding processes and choose the solution that suits your needs.
The working principle of these two machines comparison
Ultrasonic metal spot welders and traditional spot welders are both devices used to join two or more metal parts together, but they work very differently.
Traditional spot welders use resistance heating to heat two metal surfaces to the point of melting, then apply pressure to make them stick together. Spot welders need to use high current and voltage to generate enough heat, and there needs to be a gap between the electrode and the workpiece to allow the arc to form and generate enough heat.
The ultrasonic metal spot welding machine uses ultrasonic vibration to frictionally heat the metal surface to the melting point, thereby realizing the connection. The device does not require an electrode gap between two metal surfaces like traditional spot welders because it only needs to apply pressure where the metal surfaces meet. In addition, because ultrasonic metal spot welders only need to use lower current and voltage, they are more energy efficient than traditional spot welders.
The similarity is that they both join metal parts together, but ultrasonic metal spot welders differ from traditional spot welders in that the former use the vibrations of ultrasonic waves to make the join, while the latter use resistive heating to make the join . In addition, the ultrasonic metal spot welder requires less energy to work, so it is more energy-efficient.
The characteristics of the two in the course of use
Advantages of ultrasonic metal spot welding machine:
- A high-strength connection can be achieved without damage to the connection surface.
- The operation is simple, without using electrodes, which reduces equipment costs and maintenance costs.
- The heat-affected zone is small, and there will be no problems such as deformation or thermal cracks during the welding process.
- It can be integrated with other automation equipment to improve production efficiency.
Disadvantages of ultrasonic metal spot welding machine:
- Suitable for smaller workpieces, unable to handle larger metal parts.
- For some difficult-to-process materials such as aluminum alloys, magnesium alloys, etc., the connection quality may not be as good as traditional spot welding machines.
Advantages of traditional spot welders:
- Larger metal parts can be welded.
- The welding speed is fast and mass production can be realized.
- The quality of the connection is more consistent and easier to control.
Disadvantages of traditional spot welders:
- Higher currents and voltages are required to generate enough heat to adversely affect the environment.
- It is easy to cause problems such as deformation and thermal cracks, and subsequent processing of the workpiece is required.
- Electrodes are required, increasing equipment costs and maintenance costs.
Through comparison, it can be found that there are obvious differences between the ultrasonic metal spot welding machine and the traditional spot welding machine in terms of operating principle, scope of application, and connection strength.
Ultrasonic metal spot welding machine has the advantages of simple use and small thermal impact, but it is limited by the size of its welding parts and the disadvantages of materials that are not easy to process.
The traditional spot welding machine has the advantage of being able to handle larger metal parts, with high production efficiency and connection stability, but there are also disadvantages such as environmental pollution and the need for subsequent processing.
Therefore, when selecting the appropriate metal spot welding equipment, the type should be selected according to the actual needs, and the cost, efficiency, energy consumption, manufacturing quality and other factors of the equipment should be considered comprehensively.
Ultrasonic metal spot welding machine and traditional resistance spot welding machine are two different metal connection technologies, and they have significant differences in terms of working principle, performance characteristics, and scope of application.
The traditional resistance spot welding machine uses the principle of resistance heating to heat two metal parts to a molten state under the clamping of the spot welding head, and apply pressure to make them bond. This method is often used on materials with good conductivity such as steel and aluminum alloy, and has the advantages of simple operation and low cost, but it does not work well on non-conductive materials or materials with large thickness.
In contrast, the ultrasonic metal spot welding machine uses high-frequency vibration to generate heat energy, focuses the energy on the contact surface of the spot welding, makes it heat up and melts rapidly, and then combines it by applying high pressure. This method can handle different thicknesses, non-conductive materials, and welding tasks that require high precision and aesthetics, and has the advantages of high efficiency, low heat-affected zone, and no need for surface cleaning.
To sum up, ultrasonic metal spot welding machines and traditional resistance spot welding machines have their own advantages and disadvantages, and in actual use, they need to be selected according to factors such as materials and processes.