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90º Cold formed

Resistance welding consummables: Why making them by cold forming?

In DEM we are able to bend the copper (Cu) bar/rod up to 90º with a minimum radius; this cold forming is the result of the application of our own technique developed by our Engineering Team - that is not based on the classic process of bending; the result is the large part that appears on the photo. Previously, this type of pieces could only be made from plate or casting.

Which are the advantages of cold forming resistance welding consumables requiring a 90º angle?

When working the bar material with this technique, we achieve a homogeneous continuity in the material fibres along the whole piece.

The cold forming also allows us to replace the shank adapters that are welded to the end of the arms. The result is a single piece.

With the conventional bending process there is a need to weld the two pieces together. With the cold forming process, we eliminate the risk of leaks from this area as there is no join; therefore the whole unit is very strong and has no weak points:

The minimum radius on the inside allows the gun designer to close the welding point to the body of the gun. With normal bends this cannot be done to the same degree. In this way we are able to reduce the length of the arm and, therefore, to diminish its flexions at the moment when applying the pressure for welding and, also, lighten the weight of the whole set.

The fiber compaction that is obtained with the cold forming of the material extends the life of the piece.

Resistance welding consumables:  Why not do it from casting?

Almost any piece can be obtained from casting; nevertheless this technique has become old fashioned and can be subject to porosity resulting in water leakage and a tendency to break far more easily once subjected to normal weld pressures. In DEM we do not recommend its use for these very reasons.

Resistance welding consumables:  Why not do it from plate?

Cutting from plate is quite wasteful as there are always useless pieces of plate left over which in the main are too small for further use.