Alternating Current Welding or AC welding refers to the type of power supply that is used in AC Resistance Welding. AC welding uses a constant flow of energy generated from an AC Transformer. This transformer can be controlled to generate very fine welds.
The AC welding systems are primarily used to create seam welds using the continuous flow of energy from the AC Power supply. This unit will continually flow weld energy as long as the trigger is pressed. This allows for hermetic sealing of pouch cells and any foil welding. This also allows for every wire in a mesh to be welded to the substrate, giving a strong, reliable and repeatable weld. Used for mesh welding screens, mesh basket welding, Filter welding, and Filter tacking.
Capacitive Discharge resistance welding or CD Resistance welding uses capacitors to store energy for quick release. A capacitor, like a battery, store energy for release. Unlike a battery, a capacitor has the ability to release energy at a much higher rate.
CD Resistance welding uses the microscopic gap between two parts to create heat in a very localized area. At the microscopic level, every metal has peaks and valleys. As two metals are placed surface to surface, peaks will touch other peaks. Depending on the force that is applied to these pieces, more or less surface contact will occur. As electricity passes through these peaks it causes heat to build up, and melt the peaks. This is the basic understanding of how a resistance weld is accomplished.
A DC welding system uses a Direct Current Waveform. This allows for a rapid upslope, a sustained peak, and a rapid downslope. This waveform is similar to a square, with a sharp increase in energy at the trigger, flat constant peak energy, then a sharp decrease in energy to finish. This allows for very fine control, especially on the lower end of the energy settings.
DC welding is perfect for very small and fine wire welding. DC Power supplies have the ability to control the weld current very low & precise. One of the major applications for the DC Welding systems is Thermal Compression Welding. DC welding is also very useful in PCB repair, and trace welding. Additionally, DC welding is used anytime a very small wire, is being welded.
