Flash Welding

Flash welding is a form of resistance welding and forge welding combined, it utilizing the heat generated by electrical resistance and high pressure to join metals. In flash welding, two workpieces are brought into contact, and an electric current is applied, creating intense heat at the point of contact. This heat causes the metal surfaces to reach a molten or plastic state.

During the process, a flash or arc forms as a result of the localized melting or softening of the metal. Pressure is then applied to the workpieces, allowing them to forge together and create a solid welded joint. Subsequently, any excess material formed during the welding process, known as flash, is typically removed.

Flash welding is commonly employed for joining large cylindrical metal components, such as pipes, tubes, and rails. It is valued for its efficiency, speed, and ability to produce strong, high-quality welds. The process finds widespread application in various industries, including automotive, aerospace, and construction.

Here is an example of rebar being welded with a flash welding process: