How to prevent splashing in LPG Cylinder Spot Welding Machine
To prevent the spatter of the weld spot of the LPG cylinder spot welder, coordinated control is required from three aspects: process parameter optimization, electrode design and equipment function. In terms of welding parameters, the "step-by-step current increase" mode is adopted, and the initial current is set to 60%-70% of the rated value (such as 40-50kA), and it is slowly increased to the peak value after 1-2 cycles to avoid the metal overheating and spattering caused by instantaneous thermal shock; at the same time, the welding time is controlled at 10-20 cycles, and the electrode pressure is 0.2-0.5MPa, so that the molten core is stably formed under the wrapping of the plastic ring. For example, when welding a 3mm thick carbon steel cylinder, the current is increased in three stages (60%→80%→100%), and the spatter can be reduced by more than 40%.
The electrode structure design adopts " boss + cone" Composite shape, boss height 0.8-1.2mm , cone angle 120° , reduce contact resistance heating by concentrating current density, and use cone surface to guide spatter to the outside of electrode. With dispersion-strengthened copper electrode (containing Al₂O₃ 0.5%-1% ), its high temperature hardness (≥ 150HB ) can reduce electrode deformation and avoid spatter caused by electrode wear.
The equipment is equipped with a dynamic spatter monitoring system, which uses an infrared sensor to capture the state of the molten core in real time. When a spatter signal is detected (light intensity mutation> 30%), a gas pulse purge (pressure 0.3-0.4MPa) is triggered in milliseconds to blow the spatter away from the weld area; at the same time, a servo electrode pressure control system is used to dynamically compensate for pressure fluctuations during welding (error ≤±2%) to prevent the molten core from rupturing and spattering due to insufficient pressure. In addition, the surface of the cylinder is sandblasted (roughness Ra 6.3-12.5μm) before welding to remove oxide film and oil stains, which can control the spatter rate of the weld below 5%, meeting the safety welding requirements of LPG cylinders.
If you want to know how to prevent weld spatter in LPG Cylinder Spot Welding Machine , you can contact Qineng Welding System, we will do our best to help you !