Resistance Welding Equipment

Flash Butt Welders and All Resistance Welding Equipment

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

Automation International is the worldwide leader in supplying flash, butt and upset welding machines for many applications from the smallest upset weld to the largest flashweld.  We have ten standard flash butt welder models ranging from Model FBW1 to Model FBW10.

Applications include: wheels, aerospace, structural members, rings, rods, anodes, bands and much more.  Our smallest Flash or Butt-Welding machines are capable of small applications including band-saw blades, wire applications, and flat stock materials.
Our largest models range from 100 Ton upset to 200 Ton upset with 500 Ton clamp force. These welders weigh up to 45 Ton.

They are available as Flash or Upset (flash less) or a combination of both.
Designed to withstand the most stringent industrial demands and environment.
Provides complete, precise control of the entire weld cycle.
Covers the full range of welding applications in weldable ferrous and non-ferrous materials up to a maximum capacity of each unit.
Available in models with Single-phase AC transformers or Three-phase DC and MFDC power supplies.

Experienced Sales Engineers will evaluate your application and process to determine the size of welder and tooling arrangement to fit your needs.

The flash and butt (upset) welding process provides an excellent weld quality using no filler materials and requires no flux or gas coverage and is extremely fast.

Aii welders are available in standard or custom clamping mechanisms for vertical, horizontal and angular applications. Horizontal slide style clamps for straight butt welds, or on an angle for miter welding. For special applications, combinations of vertical and horizontal clamps can be supplied.

Resistance Seam Welding Machines

Resistance seam welding is a process that produces a weld at the interface surfaces of two similar metals. The seam is usually an overlap joint and can either be a manual or automated process. Like spot welding, seam welding relies on two electrodes, usually made from copper, to apply pressure and current.

The electrodes are disc shaped and rotate as the material passes between them. This allows the electrodes to stay in constant contact with the material to make long continuous welds. The electrodes may also move or assist the movement of the material.  Seam welding produces an extremely durable weld because the joint is forged due to the heat and pressure applied. Seam welders provide gas-tight seams or roll spot in circular or longitudinal welding configurations. Automation International designs and manufactures a large range of standard resistance seam welding equipment and special resistance seam welding machines.

Spot Welding Equipment

Spot welding is a process that uses two shaped copper alloy electrodes to concentrate welding current into a small “spot” and to simultaneously clamp the sheets together while forcing a large current through the spot will melt the metal and form the weld. The attractive feature of spot welding is a lot of energy can be delivered to the spot in a very short time. That permits the welding to occur without excessive heating to the rest of the sheet. Aii provides an entire line of spot welders both A.C. and D.C. for the entire metal-working industry.

Projection Welding Machines

Projection welding is a modification of spot welding. In this process, the weld is localized by means of raised sections, or projections, on one or both of the work pieces to be joined. Heat is concentrated at the projections, which permits the welding of heavier sections or the closer spacing of welds. The projections can also serve as a means of positioning the workpieces. Projection welding is often used to weld studs, nuts, and other screw machine parts to the metal plate. It’s also frequently used to join crossed wires and bars. This is another high-production process, and multiple projection welds can be arranged by suitable designing and jigging. Aii can provide an entire line of either manual or automatic Projection Welders.

Automated Butt Weld Line