Analyzing the Causes of Incomplete Welding and Burrs in Medium Frequency Spot Welding Machines

After prolonged use of medium frequency spot welding machines, both mechanical and electrical states may decline, leading to various minor issues during the welding process, such as incomplete welding and burrs at the weld points. Here, we’ll analyze these two phenomena and their causes:

Incomplete welding refers to when the diameter of the weld nugget is smaller than the specified minimum diameter, manifesting as a whitish appearance at the weld point. This phenomenon mainly occurs due to inaccurate welding parameters, insufficient current input, or a short welding time, leading to incomplete fusion. Other reasons include:

Weld points being too close, causing current shunting during spot welding.

Shunting occurring when welding copper pads.

Larger electrode end faces increasing the contact area between the workpiece and the electrode.

Distortion of the weld point.

Impurities on the surface of the electrode head or the plate.

The causes of burrs at the weld points mainly include:

Excessive welding current.

Insufficient welding time.

Formation of edge weld points.

Impurities or oil stains on the surface of the workpiece.

Insufficient size of the electrode head end face.

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