Suspended Spot Welding and Duty Cycle Consistency
Suspended Spot Welding is a unique welding process utilized in both spot welding and direct gas flame welding processes. It is considered to be one of the most robust welding methods in the industry. It can produce welds that are stronger, lighter, and more accurate than other common welding methods. There are many reasons why this unique welding method is used by many industries. If you are considering using a Welding Induction or Tip Dresser to conduct welding operations, you may want to review the differences between Suspended Spot Welding and Tip Dressers first.
Suspended Spot Welding utilizes two-part welding technology. The first difference between a standard stand mounted Welding gun and a suspended Welding gun is in the location where the arc or torch comes from. The suspended welder welds by placement of an inert gas like argon or neon between the welded point and the tip of the welder’s arc; the inert gas prevents impurities from mixing with the weld and interfering with the arc. As a result the weld is more accurate and stronger than stand mounted welds.
The second difference between the standard welders and suspended spot welding equipment is in the type of feed rollers that are used. When working with standard welders, the feed roller moves up and down along the weld puddle. This forces the welder to consistently move his/her arm in and out of the weld puddle. In the case of the welder using an induction welding equipment, the weld puddle remains constant. The welder does not need to move his/her arm or head to adjust the position of the weld puddle.
With the use of an electrical immersion gas such as argon, neon, krypton, or some other inert gas the welder is able to create a steady arc that maintains a consistent weld puddle location. Because the welding machine is free of mechanical parts that could be subject to wear and tear, the user is able to get more work done in less time. This type of welding machine also allows for a higher degree of control over the current control. Generally, the higher the input current to the smaller the pulse width and the smaller the pulse duration; this allows for a very precise arc to be created and maintained over a wide area.
A typical welding machine can have many different options for the input current, which is important for the overall efficiency of the Suspended Spot Welding process. The type of welding current, if any, that is used is determined by the welder’s welding requirements, the type of material that will be used, and possibly the operating environment. Some of the common methods of welding that utilize the standard electrodes are:
When the spot welding process is completed then the duty cycle, the pulse width, and the pulse length will all have been adjusted so that the welder is capable of proceeding with further welding. Typically a high duty cycle will allow the welder to complete the task in less time, but a lower duty cycle will make it easier to maintain the arc, thus increasing productivity and preventing costly rework due to fatigue. The pulse width refers to the amount of pulse width that is allowed to continuously flow through the welder. In short, the higher the pulse width of the finer the arc produced and the shorter the pulse length. Typically the lower the pulse width, the smaller the spot size that is produced and therefore the smaller the overall weld puddle.