Spot welding 99.9% Aluminum with DeltaSpot

Resistance Spot Welding with the Fronius process DeltaSpot. Indexing ProcessTapes allow
perfect welds on aluminum. This video should show how simple it is to spot weld aluminium with DeltaSpot.
You can see, I still are able to hold the plates. The reason is the low current you need with DeltaSpot.
The additional resistance from the tapes are a boost for the energy and therefore a weld current of 13kA is more then enough.

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Science & Technology

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• DeltaSpot
• 005

[UncleLeonFourBarrel]

Is it safe to do any type of electric fusion welding without gloves??

[marcheseDS]

@Fronius09 Thank you, I was puzzled about that...now it is clear. Keep the electrodes clean was out of my mind since I was reasoning about electrical paths, not thinking about the process engineers point of view of reliable and repeatable action (I have never done a spot weld yet...) Neat solution

[Fronius09]

@xZer0nex Thank you

[Fronius09]

@marcheseDS With DeltaSpot you never turn back in the normal spot welding scheme since your electrodes are always clean. In case of shunting you are again right. If you use a low resistance tape, you turn in regards of parameters back to conventional spot welding but your electrodes stay still always clean which reflects in high quality and stability of your process.

[Fronius09]

@marcheseDS It is based on MF DC Inverter technology (1000Hz). In the area where you but pressure (welding force) on the aluminum are the electrodes and the tape. The applied welding current has to flow, in order to pass through the already existing "shunt" weld, through the tape. This tape generates due to its high resistance energy on the surface of the alu.

Shunting is present if f.e. the alu gets to thick (>1.5mm) or due to welding requirements (f.e. class A surface) with low res. tapes.

[marcheseDS]

@Fronius09 Being Fronius a famous inverter producer I bet it is inverter driven right? But it uses frequencies in the RF range so the tape can add an impedance to avoid shunt effect? I still cannot see how adding something in series with the electrodes can actually lessen the effect of a parallel path shunting the current...with a very low resistance tape it would seem to me that you turn back to the normal spot weld situation, I miss something in the scheme.

[Fronius09]

@marcheseDS You are right. Due to the process tapes the material is starting to melt from the inside (between the sheets) and from the outside. Fronius offers different process tapes for different applications. For example for class A surface quality we use a process tape with a very low resistance and prevent the material to melt up on the surface.

[marcheseDS]

@Fronius09 This heat build up due to the tapes is actually heating/melting the aluminum from the outside instead of the inside as in usual spot welding? It seems different from the spot welding we usually see, can you explain it please?

[xZer0nex]

@Fronius09 Very cool.

[Fronius09]

With DeltaSpot, shunting on aluminum is almost zero due to the high resistance of the process tapes. The tapes create a massive amount of energy exactly in the area of the nugget.

This elimination of the shunt effect counts for materials (aluminum alloys) up to 1.5mm single sheet.