Breaks in wires that are due to failure of the butt weld that spliced the trailing end of one wire to the leading end of another wire to maintain a continuous process. A break for this reason appears as a 90 degree or as a “fish-mouth. This is usually a result of a poor welding technique or faulty equipment. Such breaks often occur in the first few die reductions on a wiredrawing machine.

Debris and excess material from welding sparks fusing around the weld during welding operation. In wire butt-welding, the flash must be removed before the wire is sent to the next operation.

1) A process that joins metals by the application of a flame or an electric current to heat and fuse the metal edges to be joined using the material from a welding wire or rod to complete the joint. 2) A process using pressure and/or current to heat and fuse the edges of the pieces to be welded without the use of any other material, as in spot or butt welding.

Very flexible cable used for leads to the rod holders or arc-welders.

The welding process to join metal wires must be done carefully to suit the characteristics of each metal to be joined. Some of those aspects are noted in the following listings.

Brass wire has similar welding characteristics to light alloys, due to its good conductivity and low specific electrical resistance, although this varies considerably with the specification of the brass. From a resistance welding point of view, the harder the brass, the easier it is to weld.

Welding of Metal Wires, Galvanized.

In fabricating articles from light alloy wire, the timing control must be of the fully synchronous electronic type, fitted with step less phase shift heat regulation with the possible addition of “slope” control. Welding currents for light alloys are necessarily high due to the high heat conductivity and low electrical resistance of this range.

A spot or projection weld in a steel having a carbon content of 0.20 percent or a low-alloy steel will tend to be crystalline in structure and consequently brittle if it has not been sub­jected to some form of post-heating to nor­malize the heat affected zone.

Very precise weld timing apparatus must be employed in fabricating articles from stainless steel wire, as the weld setting is most critical.

1) Rod (rolled, extruded, or cast) produced for use in joining metals by welding. 2) Rod that is manufactured to special requirements as to chemical composition and surface cleanliness for use in joining metals by welding.

Material that has been manufactured to special requirements as to chemical composition and surface cleanliness for use in joining metals by welding.

Two rods or wires joined end-to-end, particularly to allow for the continuous drawing of coils of wire. Typically, the tail end of a rod or wire coil in process is welded to the lead end of a new coil so production can continue without interruption. Butt-welding is performed with either electric resistance welding machines or cold pressure welding machines. A butt weld can be made in most ferrous and nonferrous wire materials.

A welding process which uses high pressure and plastic deformation to produce metallurgical bonds. The process works at room temperature and does not require electrical or other auxiliary heat. The materials to be welded must have sufficient ductility to permit the required plastic deformation, and must not work harden easily.

Welding where a point contact is provided by the natural incidence of the two wires, and consequently a localized area offers high resistance to the flow of welding current. This type of joint, therefore, is projection welding. The interfaces rapidly reach welding heat, and, mechanical pressure is available to forge the joint into a homogeneous weld with a strength factor comparable to the parent material.

Resistance welding in which the components are brought together after the voltage has been applied so that sparking and local arcing take place for a predetermined amount of time, heating the contact areas progressively and burning off portions of them. The whole surface is thus brought up to the welding temperature, and a force is applied, joining the parts together to make the weld. Flash welding will usually result in a higher weld strength with a much smaller flash or upset burr.

Any welding process in which the weld is made without mechanical pressure.

A fabricated fixture to hold parts, e.g., wires, in a precise location during a welding operation.

Resistance welding in which one or more areas of contact, in the form of projections, are made in the components before welding and in which a number of welds may thus be made simultaneously by means of projection welding dies. Current and pressure are auto­matically concentrated at the welding points and the electrodes are designed to only transfer the current and pressure as opposed to spot welding, where the necessary con­centration is obtained by special shaping of the electrodes; cross wire welding is therefore an example of projection welding.

Welding by a heavy current passed for a certain period through two or more metal components squeezed together by a substantial pressure. Heat is generated by the electrical resistance of the work pieces to the passage of this current and they are forged together to form a weld without the addition of filler metal.