Welding Strands: Wire and Strand Welding Machines

Welding strands requires precise machines, clean welds, and reproducible processes. iDEAL-Werk is a manufacturer of industrial welding machines and develops wire and strand welding machines for strands, stranded conductors, sector conductors, and solid conductors made of aluminium or copper.

The LS series wire and strand welding machines are designed for the efficient joining of strands and wire ends using the chamber welding process. This produces a homogeneous, pore- and burr-free connection with a clean surface and minimal enlargement at the weld.

The machines are used in industrial production environments where wires are welded, stranded conductors are joined, or strands are prepared for subsequent processing steps. The compact and robust machine design with intuitive operator guidance supports reliable day-to-day production.

Used worldwide, iDEAL-Werk LS series wire and strand welding machines have demonstrated their quality and reliability for decades.

Welding Wires Using the Chamber Welding Process

In the chamber welding process, the strand or wire ends are inserted into a tube, i.e. a chamber made of glass, ceramic, or graphite. The ends meet inside this chamber. The material of the welding tube depends on the strand or conductor cross-section as well as the power of the welding machine.

Once the welding process is started, the two ends are melted by the current flowing through them and joined together under continuous feed. After completion of the welding process, the tube is broken away.

The weld is burr-free, clean, smooth, and has only minimal enlargement. This allows the connection to be drawn into the inlet nozzle of a downstream extruder with minimal rework. The chamber welding process is suitable for standard conductor constructions as well as fine-stranded, highly flexible conductors.

Typical Applications for Wire and Strand Welding

The LS series wire and strand welding machines are used for applications where strands, stranded conductors, or wire ends need to be joined reliably. These include industrial applications for welding strands, welding wires, and joining wire ends

• Strands made of aluminium or copper
• Stranded conductors made of aluminium or copper
• Sector conductors
• Solid conductors
• Fine-stranded, highly flexible conductors
• Standard conductor constructions
• Wire ends prior to downstream extrusion processes
• Industrial applications for welding and joining wires