Pressure welding method

Capacitor discharge welding

Capacitor discharge welding - high currents, minimal welding times

Even though capacitor discharge welding (KE welding) is often still considered somewhat exotic among the welding technologies, the fact is that it can generate high welding currents in an extremely short time. And that is why it is often first choice for process-reliably solving welding job problems. On top of that, machines that work with this method often get along without any water cooling. That achieves cost advantages.

KE welding with capacitor batteries that charge and discharge

Machines for KE welding are equipped with a capacitor battery that charge up during standstill times. For example when the machine is being populated with new components. That can be completed in less than 1 second but could also stretch out across several seconds. The concrete charge time depends on how the mains connection is setup. If you have several seconds available, a completely normal socket-outlet could suffice for charging. As soon as the machine starts welding again, the freshly charged capacitor battery is discharged in a few milliseconds through a transformer. The welding energy during this is aligned exactly to the nugget you want to produce. The material in the direct vicinity is practically not heated up at all. That is why capacitor discharge machines can even be operated in part without any water cooling. The number of capacitors is variable. If you need higher welding currents, we will simply install more capacitors. That means with capacitor discharge welding machines you can achieve strengths of up to 800,000 amperes.

The KE welding method in automated production

Capacitor discharge welding can be used for spot and projection welding and is used especially for joining the following materials:

  • Galvanized and hot-dip galvanized sheet metals
  • High-alloy steels
  • Grain-refined construction steel
  • High-strength and multi-phase steels (R 0.2 < 1,600 MPa)
  • Steel types with high carbon content (greater than 0.2 %)
  • Different materials
  • Surface-coated components
  • Workpieces with a wide range of different cross-sections and surfaces

In a nutshell: Capacitor discharge welding is perfectly suited to take care of welding jobs with process reliability.