HF/Heat Welders – regardless of their type – are perfectly suited to the needs of the industrial market, production or the finer requirements of the commercial sector, for example. The rapid bonding of given components – from metal to foil – produces durable and long-lasting parts or materials.
Welding technology boils down to the permanently joining the components and structures in question by means of temperature. The natural areas of application are metal components or plastics. These, with the use of machines and tools profiled for this purpose, provide a permanent joint by transforming the plastic state of the object in question. After this stage has been reached, the welders – through pressing the parts together – fuse them together so that they achieve a flexible effect at the interface between the two planes. The welders, through the variety of technology used, may be perfectly adapted to the implementation of a particular project.
Types of welding: from induction to friction
Although welders have been commonly seen mainly through the prism of heat, this technology extends much further. This is because it includes electric resistance welding, with the use of a hot plate or heated air, or induction and spark welding solutions. Among the types of welding are also the following methods:
- diffusion
- focal
- current – using high frequency
- friction; including the use of welding material
- ultrasound
- explosive
- vibration
- short-circuit crush
The variety of solutions provides the freedom to adapt the welding technique to suit specific needs. Nonetheless, welders can be reduced to a common denominator as tools essential to the joining process with the use of:
- heat sources
- clamping forces
- heating the native material to a softening state.
From this, welding – as well as welders – may be divided into solutions:
- resistance
- friction
- ultrasound
- diffusion
- explosive
- flame.
Types of welders vs heat treatment methods
The potential for use leads to three types of welders dominating the market.
High frequency welders
Dielectric devices – also known as capacitive and high-frequency welders – include power blocks, high-frequency generator blocks, a matching circuit and working electrodes. The energy feeding the welder is processed by the first block; in the second stage, a high-frequency generator generates energy at – most often – 27,12 Mhz. It guarantees the efficient plastic sealing. Their specific operating characteristics make high-frequency welders ideal for the plastics processing industry, for example. The possibilities are increasing with the optimisation of the heating process itself – including the adaptation of this method to new plastics.
Impulse sealers
Devices operating on the electromagnetic pulse principle are generally portable models, which are more mobile and suitable for sealing foil, for example. The running time is signalled by an LED located on the transformer. Indicates the operational status of the sealer – showing the time when the clamped jaws of the device can be opened, thereby generating the pulse used to join the two layers. Impulse sealers with adjustable sealing times are well suited, for example, for sealing foil bags or other machine operations requiring similar air restriction. Furthermore, models may sometimes be fitted with a shielded mechanism to ensure that excess foil is cut.
Heat sealers
Industrial equipment that enables packaging to be closed quickly and tightly. Thus, these solutions would be recommended for joints of above-average thickness – including aluminium foil. Heat sealing – also known as resistance or hot electrode welding – is performed using bench, hand, jaw and rotary equipment. Conventionally, this process involves pressing the parts in question with a heated strip against a cooler substrate, or squeezing the planes between two – previously heated – strips.
Consequently, for the effectiveness of resistance welding, the key point of contact is the gap, which as a result of the resistance it presents to the current, is brought to a strong heat. When the contact temperature transforms the state of the metal into a more ductile state, a corresponding joint is achieved through pressure or pressing. An important feature of such a solution also lies in the precision and accuracy of the process.
Points to consider when using welders
While planning the welding of the components in question – regardless of the method chosen – it is essential to pay attention to the factors that determine the quality of the joints. These range from the cross-sectional forces that occur in the parts to be joined to the sectional analysis of the strength of the parts to be joined. Also important is stress concentration or the behaviour of the material under increasing load. Welders must also be selected according to the deformability of the joint, which occurs over time during standard operation.
Application of sealer machines
Sealing machines form an integral part of many industries. They are used in the automotive, aerospaceand medical industries, as well as in the manufacture of electronic and white goods components. They are essential in production processes where a robust and durable connection of components is required. For the packaging industry, such machines serve to seal foil, creating airtight packaging for a variety of products. In the clothing industry, sealing machines can be used to join materials in the production of protective clothing, such as waders with integrated wellingtons.
Good quality sealing machines are essential for numerous industrial processes where the highest precision and durability of the joints is the primary objective. Some examples include the automotive, aerospace, marine, energy or medical, industries, where product quality requirements are extremely high.
Choosing the right sealing machines and their supplier
Choosing the right sealing machine is dependent on a number of factors. Firstly, the type of material to be welded must be taken into account. Another key criterion is the size and shape of the parts to be welded. Some machines are designed for welding large, flat surfaces, others for small, precise parts. The right choice of the size of the machine and the power of the generator ensures the most optimal working efficiency and energy consumption. As a provider of solutions in the field of industrial technology, we also provide technical support and training in machine operation. Our company provides a full warranty and post-warranty service. Another important consideration is the price of the machine and operating costs, such as energy consumption or spare parts.
That being said, as you can see, choosing the right sealing machine is quite a challenge. This requires a well-considered decision, which takes into account many factors – starting with the type of material, the size and shape of the components, to the pace of work, ease of operation, service availability, and finally price and running costs. By choosing the right business partner, you can gain the type and profile of welder that will ensure that the machining process becomes optimal in terms of quality and machine performance.
