A precision welding that is used to join different small parts together is known as micro welding. This is a careful type of welding. It is performed in small areas where it is required that the parts near welding are not damaged.
In this process, the surface tension, fusion extend, deformation, and all the requirements of welding should be fulfilled. This process requires skills in order to perform welding of even micro components or areas.
The major use of the process is found in the electronic and electrical industries.
Micro-welding is also considered when no sparks are allowed in the metals that are joined.
The machines used for this process must be extremely accurate. The machines designed for these applications have unique features and are completely different from industrial resistance or arc welding machines.
Micro welding technique is used since beginning of 20th century. One of the first companies using it was Ford as a development for some applications from the standard resistance welding technique.
It was developed in order to be able to weld high melting point alloys inside vacuum tubes. Some non-ferrous materials, as tungsten, molybdenum or nickel alloys can only be welded to ferrous materials using micro welding.
This process was also used in dental surgery.
After that, there was a need for welding in the electronic industry to join small components with high precision.
This process was then used in the welding of different materials that were required in human body.
Micro welding is a technology that opened a new path for the engineers to weld different parts where high precision and minimum detrimental of the parts that are welded are required.
It is possible to weld parts using micro welding technology of a joint-wall thickness less than 0.5 millimeters.
Micro welding is a precise process that can produce welding beads of 0.065 up to 0.005 mm.
The technique requires precise heating to prevent adjacent parts from damage.
This technique is useful for the precise fusion of the very small components.
It is a delicate process that requires experience and patience from the welder, who must perform a weld of minimum size.
As micro welding is done on very small scale, it needs special equipment and machines.
Also the welder who executes these welds should have proper skills of using proper equipment.
The success of the process completely depends on a combination of quality of the equipment used and welder’s skills.
Some of the necessary equipment required for this process is:
Micro welding can be executed using different welding process. Some of the actual industrial solutions are as follows:
The laser is in the solid-state. Automated programmable or manual machines are used in this accurate welding process. Micro laser welding provides the best welding quality thanks to its penetration power.
This technique does not apply pressure on the surfaces that are welded. Also there is no need for a vacuum chamber since the laser beam can travel through the air easily. There is no need to use shielding gas, but can be used for some applications. This method can be used for welding the highly reactive metals.
This technique is very useful as it does not produce any environment contaminating gas.
This uses equipment capable of very accurate control of just a few amps output power. The welding torche used for this type of micro welding is the size of a pen.
This technique is useful in welding very small components of high alloy density.
Flash micro welding uses high pressure to produce cost-effective and high-quality joints. This welding process is used to weld components as thermocouple wires.
The welds obtained with flash micro welding are good looking joints. Many beautiful chains of precious metals are built using this welding technique.
Another typical application is the joining of band saw or cable ends with great precision and quality.
This technique is derived from large scale resistance welding.
In micro resistance welding, the spot welds are performed with high precision and quality. This process needs very tiny electrodes for operation. The electrodes supply proper current for welding while pressure is applied by the welder.
This technique is suitable for the proper alignment of micro-elements. The high-quality projection welding can be performed using this resistance micro welding.
Another interesting variation of this process is the welding of micro-balls that are used as “tack-welds” to hold together components that will be welded later on using brazing or a different welding technique.
The micro welding technique requires an expert welder. The welder must have all suitable equipment for the process.
Each application require an expert aproach in order to find the technique that best fits the needs and requirements.
Let our experts guide you in the most adequate technique for your particular application.
Solutions for high-precision, high-quality micro-welding applications.
SOUDAX has extensive experience in the design and manufacture of equipment specialized in micro-welding solutions, and in complete installations that ensure repeatability of results, while recording the results obtained.
Manual, semi-automated or automated welding solutions.
Micro-ball welding allows the preparation of components to be welded by any arc welding or hard welding process.
The microballs, with a diameter between 0.8 and 1.6 mm, and of the appropriate material, leave the joints to be welded pre-tapped, assuming a minimum heating and deformation of the joints, and allowing an optimum separation, suitable according to the thickness of the materials to be welded and the chosen welding process.