Wire diameter selection for DENSO robots

Create Date: 2024-8-30 12:03:23|Source: Denso/DENSO

Select the right wire diameter for welding

                                 Wire diameter selection for DENSO robots

The main consideration in selecting the diameter of the wire is the thickness of the material to be welded. If the wire is selected that is too small for the data, the welding process is underpowered, and time and production costs are wasted, as the welder has to spend more time completing the weld. Because the weld may not be able to fully penetrate the data, it can also cause quality control problems. Another problem with using wires that are too thin is the arcing inside and between the top grades, which can corrode the top inner diameter and eventually cause the top grades to be fused to the wire.

However, it is not always possible to simply select a large diameter conductor. If the wire is too large, it may degrade accuracy and can lead to quality control issues as other parts of the product may not fit correctly. This can also cost you power and data when it comes to cleaning up too much or adding more production steps after the welding process. It can also lead to clogged iron tips, excessive feed force and wire slippage. When these issues are addressed, all of these issues can lead to production line downtime, which can reduce your labor and productivity.

In addition to picking the right size, you also need to make sure that the wire diameter you achieve is the same. Why? Uneven diameters can prevent proper current flow between the wire and the contact. When the ends of the wires are joined together by defective wires or through butt welds, the diameter will eventually change. AWS-compliant wires can vary by up to 8% in weld seam build-up. Conductors that have been inspected with a laser micrometer guarantee the best commonality.

By selecting the right wire diameter for your welding job, you can ensure that your production runs efficiently while still providing the precision you need to produce a quality product.

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