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Flash & Butt Welding Controls & Monitors

WeldComputer Adaptive Control Regulates Consistency of Flash & Butt Weld Process While Reducing Power Consumption

Flash Welding

Flash welders can cause flicker and unacceptably severe demand on the factory power line.


  • Control: in many applications, replacing the existing flash welder control with a WeldComputer Control has been demonstrated to reduce flicker on the power grid to acceptable levels.
  • Adding adaptive features to the flash welding process further reduces current demand on the power line, while improving the flashing capability and flashing consistency of the machine, which increases upset consistency and the consistency of the welded product.

Replacing the existing control with a WeldComputer Adaptive Control for flash welders is the easiest action to take to:

  • Increase flashing consistency
  • Increase flashing capability
  • Increase energy efficiency
  • Reduce current draw and flicker on the power line, and
  • Provide balanced distribution over all power line phase.

Butt Welding

Butt welding operations using conventional controls are faced with:

  • Variations from lack of coordination of the heat control with the action of pressing the part together
  • Inability to compensate for the variable surface conditions of the contacting parts being welded, and
  • Inability to compensate for upset variations.


  • Adding Adaptive Control further improves weld consistency by synchronizing the application of heat with the contacting parts, and automatically adjusting the heat to compensate for part variations. This results in increased upset consistency, increased reliability of the welded result, and reduced rejected parts.

Replacing the existing control with a WeldComputer Adaptive Control for butt welders is the easiest action to take to:

  • Increase heating consistency
  • Increase upset consistency
  • Increase weld quality
  • Increase energy efficiency
  • Reduce current draw on the power line, and
  • Provide balanced distribution over all power line phases.

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Flash & butt welding are similar in that both require consistent heating of the part, followed by consistent upset.

In the case of flash welding, the heating is caused from heat generation from the current flowing within the material itself. Otherwise the processes are similar.

Consistent heating of the part prior to upsetting is required to achieve consistent upset, and consistent upset is required to produce a consistent weld.

When an operation is faced with inconsistent weld quality because of inconsistent heating from an inconsistent control, instead of installing a monitor to report all the inconsistencies, replacing the control with a WeldComputer Adaptive Control will improve the consistency of all welds and reduce the number of failed welds produced in the first place. Then to detect whatever random problem welds from other causes occur, instead of adding a separate standalone monitor, adding monitoring functions on top of the control provides a higher performance WeldComputer Control with Monitor solution that is easier to manage by the welding operation.

Many clients rely on WeldComputer to solve their resistance welding needs. Contact us for more information and a free consultation to see if WeldComputer is right for your resistance welding application.

Email us or call us at 800-553-9353

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WeldComputer technology is protected by the following U.S. Patents: 4,714,913 4,742,473 4,803,331. Other Patents Pending.