Which Is More Suitable for Welding Automotive Thin Plates, Pulse Welding Or Continuous Welding? What Is The Speed Difference?

Pulse welding and continuous welding each have their own characteristics when welding automotive thin plates. Generally speaking, pulse welding is more suitable for welding automotive thin plates. The following is a specific analysis:

Reasons why pulse welding is more suitable

1. Small heat affected zone: Pulse welding is performed by pulsed current, which generates heat during the pulse period to melt the material and form a solder joint. During the pulse pause period, the heat input significantly decreases. This can accurately control the heat input, reduce the thermal impact on the surrounding materials of the car sheet, lower the risk of deformation, and better maintain the dimensional accuracy and surface quality of the car sheet.

2. Good weld quality: Pulse arc has a strong stirring effect on the molten pool, and the cooling speed of the molten pool is fast, with a short high-temperature residence time, making the weld metal structure fine and can effectively reduce defects such as pores and cracks, and improve the performance of the weld.

3. Good arc stability: When the welding current is low, the general welding method is prone to arc drifting, while pulse welding has good arc stiffness and stability, which can ensure the stability of the welding process, especially suitable for thin plate welding.

Speed difference analysis

The speed difference between pulse welding and continuous welding in welding automotive thin plates does not have a fixed value and is influenced by various factors such as equipment performance, material characteristics, welding parameters, etc. The general situation is as follows:

• Pulse welding: Generally speaking, pulse welding forms welding points one by one. Although the welding speed of a single pulse is fast, it requires multiple pulses to complete a weld, and the welding speed is relatively slower compared to continuous welding. When welding automotive thin plates, the speed of pulse welding is usually around tens of centimeters to one meter per minute. For example, in some processes that use pulsed laser welding to weld automotive thin plates with a thickness of less than 1mm, the welding speed may be around 30 to 80 centimeters per minute.

• Continuous welding: Continuous welding is the process of continuously outputting energy for welding, resulting in a more coherent weld formation and theoretically faster welding speed. When welding automotive thin plates, if using continuous laser welding or other processes, the speed may reach one to several meters per minute. For example, when using high-power continuous laser welding to weld 1-2mm thick automotive sheets, the welding speed can reach about 1.5 to 3 meters per minute.