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Amada Miyachi Blog

Marty Mewborne

Recent Posts

Resistance welding trouble shooting: 7 simple steps

Posted by Marty Mewborne on Thu, May 30, 2013 @ 08:18 PM

You've been successfully running the same resistance spot welding program for days - months - years when all of a sudden it stopped working.  What do you do?  Where should you start?  When troubleshooting a problem with your resistance welding process, we've learned that it's best to start with the materials and move back toward the power supply.  Troubleshoot using 7 simple steps, in this order:

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Topics: resistance welding troubleshooting, Resistance welding, resistance spot welding

Battery Pack Welding: Better Performance and Higher Currents

Posted by Marty Mewborne on Thu, Mar 28, 2013 @ 08:00 AM

Battery tabs seem to have been getting thicker and more conductive over the last several years, as customers seek better performance and higher currents from their battery packs. These thicker battery tabs are usually made of nickel, but nickel-plated copper tabs are gaining in popularity due to their higher conductivity.  We’ve had success welding the thicker nickel tabs, but have found the nickel-plated copper to be very difficult to weld.  How to overcome that?  Add slots and projections to the tab design to focus the current and minimize current shunting.  Welding success also depends, in part, on the battery itself; those with thick caps can easily handle the high force and current needed to weld the thicker tabs.  If the battery caps are too thin, however, they may get deformed or blown through. 

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Topics: Resistance welding, resistance spot welding, battery welding

AC, DC, CD or HF: Which Spot Welding Power Supply Should I Use?

Posted by Marty Mewborne on Tue, Nov 20, 2012 @ 08:00 AM

I recently posted a blog about closed loop welders and how you can get the most out of using them, and it occurred to me that some of you may not be familiar with the different resistance spot welding power supply technologies, how they work, and what they can be used for. So here is a short description of the four different types, including both closed loop and open loop designs.

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Topics: Resistance welding, spot welding, resistance spot welding

Projection Welding: Balance Heat and Extend Electrode Life

Posted by Marty Mewborne on Wed, Nov 07, 2012 @ 08:00 AM

If you read my recent blog on heat balance, you know that there are five different techniques that can be used to balance weld heat that don’t  involve making changes to materials or part design.  And at the end of the blog I mentioned that if you’re still having difficulty after trying all five of the techniques, you may want to consider adding projections to one of the parts.

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Topics: Resistance welding, spot welding, projection welding, electronic package sealing

Spot Welding Equipment Calibration: the Key to Reducing Down-Time

Posted by Marty Mewborne on Fri, Oct 26, 2012 @ 08:00 AM

Equipment calibration may not be the most exciting activity, but it can go a very long way in saving you both time and money by reducing plant down-time due to process control fluctuations.

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Topics: Resistance welding, spot welding

Heat Balance: the Key to Successful Resistance Welding

Posted by Marty Mewborne on Tue, Oct 23, 2012 @ 08:00 AM

All right folks.  Let’s cut to the chase.  Successful resistance welding boils down to heat balance:  getting both parts up to their bonding temperature at the same time.  If too much heat goes into one part, and not enough into the other, the overheated part can become weak, and the weld won’t be strong.

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Topics: Resistance welding, spot welding

Closed-Loop Resistance Welding Control: WIFM?

Posted by Marty Mewborne on Tue, Oct 16, 2012 @ 03:53 PM

What’s the fastest and easiest way to improve your manufacturing welding processes? That’s simple: use a closed-loop resistance welding power supply! And you’re thinking “okaaay…what’s ‘closed-loop’ and why do I want to use it? I know why you want to sell it – it’s a higher end power supply that costs more money, but exactly how will that help me in my process?” Well, I’m going to tell you.

What is closed loop? At a high level, closed-loop resistance welding power supplies use current and voltage feedback sensors to precisely control the energy delivered to the parts. This ability to accurately control weld energy is a key factor in overcoming problems associated with process variation and the rapid changes in resistance that happen during the weld.

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Topics: Resistance welding, spot welding

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