Zhengye DUHANJI Series Fully Automatic Butt Welding Machine
| Brand | Zhengye |
|---|---|
| Origin | Guangdong, China |
| Manufacturer Type | OEM/ODM Manufacturer |
| Regional Classification | Domestic (China) |
| Model | DUHANJI |
| Pricing | Upon Request |
Overview
The Zhengye DUHANJI Series Fully Automatic Butt Welding Machine is an industrial resistance butt welding system engineered for high-reproducibility solid-state joining of metallic components in semiconductor manufacturing support infrastructure and precision metal fabrication. Unlike arc or laser-based processes, this machine employs controlled resistive heating—generated by passing high-current, low-voltage DC pulses through abutting workpiece surfaces—to raise interfacial temperature to forging range without melting. The process relies on precise synchronization of axial force application (upset pressure) and thermal cycle timing to achieve metallurgical bonding with minimal grain coarsening or intermetallic phase formation. Designed specifically for continuity-critical applications in semiconductor plant utilities—such as stainless-steel gas line splicing, copper busbar termination, and vacuum chamber component assembly—the DUHANJI series meets the mechanical integrity and surface cleanliness requirements essential for Class 100–Class 1000 cleanroom environments.
Key Features
- Triple-pulse discharge control architecture enabling programmable preheating, main welding, and post-weld annealing sequences—optimized for medium-carbon steels (e.g., AISI 1045, 4140) and austenitic stainless steels (e.g., 304, 316L)
- High-rigidity parallel linear guide rail system ensuring consistent axial alignment and real-time force tracking during upset stage; positional repeatability ±0.02 mm
- Integrated microprocessor-controlled current regulation with closed-loop feedback, maintaining ±1.5% output stability across load variations
- Modular clamping interface accommodating round wire (Φ1.2–8.0 mm), flat strip (0.5–3.0 mm thick × 10–50 mm wide), and tubular sections (OD 6–25 mm)
- Touchscreen HMI with password-protected parameter storage, up to 99 user-defined weld schedules, and timestamped operation logging
Sample Compatibility & Compliance
The DUHANJI series supports butt welding of conductive metals including low-carbon steel (AISI 1008–1018), medium-carbon steel (AISI 1045), stainless steels (304, 316, 430), copper (C11000), and aluminum alloys (6061-T6, when pre-conditioned). Surface preparation per ASTM B600-22 (chemical cleaning) and joint squareness tolerance ≤0.1° are prerequisites for optimal interface consolidation. The machine conforms to IEC 60204-1:2018 for electrical safety and EN 60974-1:2021 for welding equipment EMC performance. It supports GLP-compliant documentation via optional RS-485/Modbus RTU interface for integration into factory MES systems.
Software & Data Management
Weld schedule configuration, real-time current/voltage/force waveform monitoring, and historical data export (CSV format) are managed via embedded firmware v3.2. All operational events—including start/stop timestamps, operator ID, selected program number, and final upset displacement—are stored with audit-trail capability compliant with FDA 21 CFR Part 11 Annex 11 requirements when paired with validated network logging servers. Remote diagnostics and firmware updates are supported via Ethernet port (TCP/IP stack enabled).
Applications
This system serves critical secondary fabrication roles in semiconductor equipment manufacturing and facility construction: continuous stainless-steel tubing joints for ultra-high-purity (UHP) gas delivery manifolds; copper busbar terminations for power distribution cabinets in lithography tool shelters; welded mesh frames for ESD-safe cleanroom access doors; and structural splices in fan guard assemblies used in chemical vapor deposition (CVD) exhaust hoods. Its repeatable thermomechanical profile also enables qualification under ASME BPVC Section IX for P-No. 1 and P-No. 8 base materials.
FAQ
What materials can be welded using the DUHANJI series?
Low-carbon steel, medium-carbon steel, austenitic and ferritic stainless steels, oxygen-free copper, and select aluminum alloys—subject to surface oxide removal and joint geometry verification.
Is the machine suitable for cleanroom installation?
Yes—when equipped with optional oil-free pneumatic actuators and sealed enclosure variants (IP54 rated), it meets ISO 14644-1 Class 7 particulate emission limits during operation.
Does the system support traceability for quality audits?
Yes—each weld record includes unique ID, time/date stamp, operator code, program version, and peak current/force values; exportable for AS9100 or ISO 9001 internal audit submission.
Can the DUHANJI integrate with existing PLC-based production lines?
Yes—standard digital I/O (24 VDC) and Modbus TCP interfaces enable seamless handshake with Siemens S7, Rockwell ControlLogix, and Mitsubishi Q-series controllers.
