Flashbutt

Flashbutt welding, also known as flash welding, is a resistance welding process. It involves the rapid heating of two or more metal parts by passing a high electrical current through them. The process begins with the parts brought into light contact, and a low voltage is applied. As the current flows, the surfaces heat up due to resistance, causing a flashing action where material is expelled. Once the surfaces reach the appropriate welding temperature, the parts are rapidly forced together under high pressure. This forging action completes the weld, creating a strong metallurgical bond.

The flashbutt welding process is highly efficient and can join a variety of similar and dissimilar metals, including steel, aluminum, and copper alloys. It is particularly well-suited for joining long or irregularly shaped workpieces, such as rails, pipes, and structural components. The rapid heating and forging action minimize the heat-affected zone, which can preserve the material properties of the base metals. The process is automated, allowing for high production rates and consistent weld quality. However, the expulsion of molten metal can create a flash that needs to be removed. This method is widely used in industries like railway construction, automotive manufacturing, and heavy machinery fabrication.