Resistance Welding Equipment
Automation International, Inc. (AII) designs and manufactures resistance welding equipment for precision metal joining in demanding industrial environments. With decades of engineering experience, we provide equipment for applications requiring strong, repeatable welds across a range of materials and part geometries.
This video demonstrates a rebuilt Flash Butt Welder with an upgrade to Mid-Frequency DC (MFDC) power supply as it processes a welding cycle on a heavy wheel rim. This video also demonstrates our patented Assurance Plus® Control System in the bottom right-hand corner of the video as it monitors the weld throughout the cycle.
Flash Butt Welding Equipment
AII supplies flash, butt, and upset resistance welding machine models for applications from small band-saw blades and wire assemblies to large-scale components requiring up to 200-ton upset force and 500-ton clamping. Ten standard models, FBW1 through FBW10, cover capacities for both ferrous and non-ferrous materials.
- Available as flash, upset (flashless), or combination units
- Configurable with single-phase AC transformers or three-phase DC/MFDC power supplies
- Clamping arrangements for vertical, horizontal, and angular welding, including custom combinations
- Suitable for structural members, aerospace components, wheels, rings, rods, anodes, and other production parts
Flash and butt welding processes produce high-quality joints without filler material, flux, or shielding gas, while maintaining short cycle times.
Resistance Seam Welding Machines
Seam welding joins overlapping materials using continuous or roll-spot welds formed between rotating copper disc resistance welding electrodes. This method produces gas-tight seams and is used for circular or longitudinal welds in a variety of industries.
AII builds standard and custom seam resistance welding machine systems for both manual and automated applications, providing consistent weld integrity through precise control of pressure, current, and electrode movement.
Spot Welding Equipment
Spot welding concentrates current and pressure at specific points to join sheet materials quickly without excessive heat transfer to surrounding areas. AII offers AC and DC spot welders suitable for small to large-scale production, with resistance welding electrodes and tooling configurations designed for specific material thicknesses and part shapes.
Projection Welding Machines
Industries Using AII Resistance Welding Equipment
AII resistance welding equipment is used in manufacturing environments where weld strength, consistency, and efficiency are critical to production. Our equipment is applied across:
- Automotive and Wheel Manufacturing – Welding wheels, axles, suspension components, and drivetrain assemblies.
- Aerospace – Joining structural tubing, housings, and precision assemblies requiring high weld integrity.
- Rail and Heavy Transportation – Fabricating railcar components, couplers, and structural members.
- Agriculture and Construction Equipment – Producing frames, implements, and wear-resistant assemblies.
- Metal Furniture and Fixtures – Projection welding fasteners, brackets, and tubular frames.
- Energy and Utilities – Welding rings, rods, and components for power generation and distribution equipment.
General Metalworking – Spot, seam, and projection welding for diverse fabricated parts in both ferrous and non-ferrous materials.
These industries rely on AII’s equipment for its ability to perform under demanding production schedules, maintain tight dimensional tolerances, and produce repeatable, high-integrity welds.
Support and Service
All AII resistance welding equipment is supported by application engineering, operator training, and parts supply. Systems are built for long service life under continuous use, with service teams available for commissioning, maintenance, and process troubleshooting. Training programs are also available to guarantee consistent performance. Connect with us today to discuss your needs or explore our full range of welding equipment.