What is Flash Welding?

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  • Written By: Jean Marie Asta
  • Edited By: Jessica Seminara
  • Last Modified Date: 01 December 2019
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Flash-welding came into existence in the 1920s. It is essentially a type of resistance welding that has been tweaked and developed to especially suit welding large pieces of metal together. The flash welding process is common in many different manufacturing industries. Since the first flash-welding machines were built and used, there have been many different changes and improvements. Today, the machines are safer to use, and they also offer a better quality weld.

Also known as flash-welding or flash-butt welding, in this process metalworkers use a specific machine in order to get enough force on the ends of the metal to attach them. In addition, the machine needs to create enough heat to melt the metal sufficiently to join the two pieces together. While the machine makes flash-welding possible, it can’t do all of the work. An experienced operator is also needed in order for flash-welding to be truly effective.

Many different industries will use flash-welding for their different assembly purposes. Common uses of this process include making rims for tires, attaching train tracks, or creating piping. Flash-welding is so popular in these areas because of the strength it gives to the metal. It is now the preferred method over butt welding, due to its improved strength and quality, as well as the shorter time required to fuse the metal pieces together.


This type of resistance welding has made it easier than ever for companies to mass produce important metal products. With the proper maintenance and upkeep of flash-welding machines, welding machines can last for many years to come. Regular maintenance will help to ensure the safety of operators when using the machine, and it will also keep the quality of the welding high.

Anyone who is doing any type of welding, including flash, must always be aware of safety precautions. Welding involves a high degree of heat, and the machinery used can also be dangerous if not used in the proper manner. If people are going to be using a welding machine, it is important to have the proper operation manuals. There should also be the appropriate protective clothing available, such as gloves, a heavy apron, and goggles.


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