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Rust formation is one of the challenges when trying to detect weld metal. Even if a good solder is made, oxidation can build up on the soldering tips.
"Rust creates inconsistencies in welds," said Andre Young . At KUKA Robotics, Young is responsible for the business development of Tier 1 and OEM (Automotive Original Equipment Manufacturers).
According to Young, each OEM and Tier 1 sheet metal manufacturer has their own techniques for dealing with rust problems. Sometimes they grind the surface to remove the oxidation layer and other people do some chemical cleaning of the aluminum. In either case, the oxidation build-up over time will require a bandage to clean the spot weld tip.
Another tool in the tool belt for spot welding devices is RoboSpin from KUKA Robotics , the application software that rotates around the TCP (center point of the tool) during the welding process.
Prevents the tips from sticking to the metal, which improves the quality of the weld and extends the life of the tips.
"The rotation creates abrasion as the weld is created and the tips are cleaned as the rotation moves," said Young. "You get good contact with the aluminum, reduce that surface resistance, direct the energy where you want it, and create a good weld."
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