Products > Flash Butt Welding

During flash butt welding, the parts to be welded are clamped between current carrying electrodes and joined or brought together so that they touch. Then, the weld current heats these joints. A uniform heating throughout the cross-sectional area is achieved by spreading and re-establishing or restoring the contact several times.
To achieve a clean and flat or plane weld, a certain amount of material is ejected from the welding zone during the ensuing flashing action. Then, the parts are upset with high speed and with great force.
The strength achievable by flash butt welding is that of the base metal. This method is suitable for welding large surfaces and compact cross-sections in open or closed lengths.

The following examples illustrate just some of the various possibilities of this welding process.

  • Chains, rings, rims as closed lengths
  • Rails, structural steel reinforcements (welded wire mesh), profiles and hollow profiles
  • Materials: alloy and carbon steel, aluminum alloys, copper

Aside from the type of material, the most important element in selecting a suitable welding machine is the cross section to be welded. This then results in the required weld current and the upset force.

The different sizes of our flash butt welding machines cover a wide performance range.
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Upset force: 15 kN to 1 500 kN
Power at 50% duty cycle: 80 kVA to 1 000 kVA
Weld cross-section: Up to 40 000 mm² (mild steel)

The machines usually consist of three main components:

  • A machine frame with upset platen, clamping devices, and an adjustment
  • A separate hydraulic power unit
  • A PLC and an industrial PC based control unit, which may be extended by a parameter monitoring system, depending on the customer’s request.
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SU 63

SU 250

SU 500



The machines usually consist of three main components