Technologies : Welding
The primary objective of welding is to join two surfaces together through the application of current, heat and/or force. MIG and TIG welding are commonly used for assembly applications. For joining applications, AC or DC Butt Welding are commonly used. AC (flash) welding applies AC current across the weld joint, establishing an arc to heat the material (similar to stick welding), and once the surfaces are hot, upset forces join the two surfaces together. Mechanical cams, cam flash/hydraulic upset, or full electronic flash/servo hydraulic actuation can be used to control the process. DC welding, generally a flashless process, presses the joint together then applies a DC (rectified AC) current to heat the joint in a fashion similar to resistance spot welding. Again once the material is hot, it is upset together. DC (upset) welding, consumes less material in the welding process, is normally 3 times faster, uses less power, and is considerably cleaner than AC flash welding. It does, however, require sophisticated controls, and better joint preparation.
DC butt welding is widely used to join the ends of coiled bands that are subsequently rollformed into rims for automotive, truck and ATV wheels. The process requires precise control of pressure, position and current. Typically, a dedicated microprocessor provides real-time, closed loop control of the welding platen position and upset force as well as command and monitoring of the required welding current.
Why Hess?
Hess’ expertise and experience encompasses a full range of mechanical and machine control solutions. Our Sable Weld Controller can be retrofitted to both AC and DC butt welding systems. The Sabre is designed, built and serviced by Hess and often replaces older control systems for which spare parts and service support are no longer readily available. From a single machine to an entire wheel and rim production line, Hess Engineering is the only company with more than three decades of experience building systems for steel and aluminum applications with fully integrated flashless DC welding of our own design.
Our years of experience in the core technologies of band preparation, welding lines, and rim and disc assembly allow us to design and build machines that are robust and built to operate easily, efficiently and consistently to your requirements.
What Can Hess Welding Technology Do For You?
- Improve process repeatability
- Reduce scrap rates
- Increase productivity
- Enhance final product quality
- Lower maintenance costs
