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TU-Clausthal Centre for Material Technology

Pressure welding

Robot welding gun / ARO-X

  • X-type
  • Total stroke 236 mm
  • Arm length 800 mm
  • Arm distance 380 mm
  • Compensation stroke 10 mm
  • Electrode holder via ø12 mm cone
  • Max. Electrode force 5.25 kN
  • Servo-motor drive
  • "iBox" welding case with ARO MF inverter MFDC 560 in combination with MF transformer 57kVA at 50% duty cycle
  • Maximum achievable welding current approx. 23 kA
  • ARODMS 2011 control software
  • Mounted on KUKA robot type "KR210-2 2000" with automatic cap milling unit

Stationary spot welding system Bosch 600 / Nimak C50

  • Projection 650 mm
  • Width 300 mm
  • Max. Total cylinder stroke 150 mm
  • Servo-pneumatic drive with compensation
  • Max. Tong force 5 kN
  • Electrode holder via ø12 mm cone
  • Welding control using Bosch MF inverter "PSI6300" in combination with MF transformer; 111 kVA at 50% duty cycle or 65 kVA at 100% duty cycle
  • Higher-level Phoenix PLC
  • Robot welding gun and welding case mounted on support frame

High-frequency welding system for metallic materials

Process modes:

  • Discontinuous conductive welding of sheets and open profiles
  • Discontinuous induction welding of closed profiles
  • Continuous welding of steel strips / simulation HFI longitudinal seam welding of pipes

Technical data:

  • Nominal working frequency 360 kHz
  • Maximum power output 85 kW
  • Connected load 160 kVA
  • Operating voltage 400 V / 50 Hz
  • Maximum compression force 60 kN
  • Control voltage 24 V

Multi-orbital friction welding system Dyconn-100

  • Uniform heat generation on the joining surface due to constant relative speed as a result of circulating circular motion
  • Material combinations with very different physical properties possible, e.g. steel-aluminum, metal-plastic joints
  • Precise joining of non-rotationally symmetrical parts possible
  • Currently the subject of research as a further development of linear friction welding

Technological data:

  • Multi-orbital friction welding
  • Movement generated by two eccentric shafts per head, 2 orbital heads
  • Oscillation frequency up to 2x 100 Hz at max. speed of 2x 6000 rpm

Weldable product range:

  • Plastics and metals
  • Joining cross-sections: up to 400 mm² S235 JR or 50,000 mm² plastic

Control system (Siemens):

  • Adjustable parameters: Distance [mm], time [ms], force [kN], speed [°/s]
  • Parameters that can be monitored for each weld: friction time, upsetting distance, upsetting force, speed