Causes of Current Diversion in Medium Frequency Spot Welding Machines？

Current diversion, or the phenomenon of uneven current distribution during the welding process, can pose challenges in medium frequency spot welding machines. This article explores the reasons behind the occurrence of current diversion in these machines and discusses potential solutions to address this issue.

1. Electrode Contamination: One common cause of current diversion is electrode contamination. If the electrodes are not properly cleaned or maintained, contaminants such as oxides, oils, or debris can accumulate on their surfaces. This can create uneven contact between the electrodes and the workpieces, leading to inconsistent current flow.
2. Uneven Workpiece Surfaces: When the workpiece surfaces are not uniform or properly prepared, the contact between the electrodes and the workpieces may be uneven. Variations in surface condition can result in localized resistance differences, causing current diversion.
3. Incorrect Electrode Alignment: Incorrect electrode alignment, where the electrodes are not parallel to each other or not aligned with the workpieces, can lead to uneven distribution of welding current. Proper alignment is essential to ensure consistent and uniform contact.
4. Material Inhomogeneity: Some materials, particularly those with varying conductive properties or alloy compositions, can exhibit inhomogeneous electrical conductivity. This can cause the welding current to divert to paths of least resistance, resulting in uneven heating and welding.
5. Electrode Wear and Deformation: Electrodes that are worn, deformed, or damaged can create irregular contact with the workpieces. This can lead to hot spots or areas of high current density, causing current diversion and potentially affecting weld quality.
6. Insufficient Cooling: Inadequate cooling of the electrodes during the welding process can lead to overheating, resulting in local changes in electrical conductivity. This can contribute to current diversion and affect the welding outcome.

Solutions to Address Current Diversion:

1. Electrode Maintenance: Regular electrode cleaning, dressing, and replacement are essential to prevent contamination and ensure proper current distribution.
2. Surface Preparation: Properly preparing the workpiece surfaces by cleaning, degreasing, and removing any coatings or oxides helps ensure uniform contact with the electrodes.
3. Precise Alignment: Accurate alignment of the electrodes and workpieces minimizes current diversion. Using fixtures or clamps can help maintain proper alignment.
4. Material Selection and Preparation: Choosing materials with consistent electrical properties and conducting thorough material preparation can reduce the likelihood of current diversion.
5. Electrode Inspection: Regularly inspecting electrodes for wear, damage, and deformation and replacing them as needed helps maintain uniform contact and current distribution.
6. Optimized Cooling: Implementing effective cooling systems for electrodes helps prevent overheating and maintains consistent electrical properties.

Current diversion in medium frequency spot welding machines can be attributed to factors such as electrode contamination, uneven workpiece surfaces, incorrect alignment, material inhomogeneity, electrode wear, and insufficient cooling. Addressing these issues through proper maintenance, preparation, alignment, and material selection can help mitigate the occurrence of current diversion and ensure consistent and high-quality welds.