For high volumes, resistance welding is the ideal joining technique: fast, reliable and it can be perfectly automated. It is not without reason that on average, the bodywork of a car is spot welded 3,500-5,000 times. As a system integrator, AWL has extensive experience in the application of the resistance welding technique, both in robotic spot welding as in building machines for projection welding for very diverse applications.
Although this technique has been known for years, yet there are always important new developments. For example, for the spot welding of aluminum, new adaptive controls are being developed in the welding controls with the use of force sensors. AWL works together on this with reputable welding control suppliers. For testing the welds, we are designing inspection techniques using ultrasound to reduce destructive testing. This technique also reduces costs, increases reliability, and can be automated.
Spot welding is very often used to connect steel parts with each other, but this technique can also be successfully applied for aluminum. Projection welding is used among other things to weld nuts, bolts, and pins to sheet metal parts. We have developed various machine concepts at AWL for this.
AWL participates in projects, in which we explore how spot welding could also be used for the connection of fiber-reinforced plastics by the use of metal inserts. An investigation has been started on how to extend the electrode tool life for the resistance welding of aluminum, with the ultimate goal of increasing the machine output.