Word micro indicates that something is as small that it becomes difficult to see with a naked eye. But what does this mean in terms of welding? Any guess? Well, imagine something so thin that ranges from 0.0003 mm to 5mm. Now just think that in which appliances do you come to see such delicate metallic objects? Well, if you turn your head around, you may not be able to find anything placed in front of you. You will only come across such tiny and thin metallic objects with switchboards, sensitive electronics, lighting components, battery electronics, etc.
This intricate and sensitive welding process is a blessing for engineers and welders. Thanks to this procedure today, we have loads of specialized machines to make our lives easier. However, down into the upcoming lines, we will open up about this technique to make it easier for you to figure out the uses and the exact procedure of micro welding.
So, take a deep breath and prepare to start with us.
What is micro-welding?
As you know, like every other field out there, welding is also evolving with time, and newer practical techniques are emerging. Well, micro welding is also an innovative and valuable welding procedure that is acting as a life savior for the whole of humankind.
It is a procedure that is used to fuse tiny parts. These parts are almost 5mm thick or less in thickness.
Along with a significant amount of heat, a particular ratio of pressure is also applied to make metals used quickly. No solder or welding rods are required to undergo this process; it is cheaper and more effective. But remember that it is an intricate procedure that demands extra care and attention, i.e., it needs to be done by an expert.
Metals on which micro welding is used
By now, micro welding techniques are used to mold and join almost everything. But remember, you can not use micro welding for brass and galvanized steel. However, here are some of the metals you can consider using micro welding techniques.
What are the machines used for micro welding?
There are multiple welding machines in the market that welders use to complete different procedures. Here we will give you one example from the micro welding machines that most top welders are using currently. Also, its working principle is discussed below.
Orion m pulsed welding machine is used specifically for delicate welding items like jewelry and chains. It is a handy and intelligent USA-made machine that is exceptionally easy to use and handle even for beginners. It is a quick setup machine and is straightforward to use to give out permanent jewelry welds.
The principle used in Orion M pulsed welding machine
This machine utilizes a beam of electricity to generate plasma discharge. This plasma is usually a high-temperature product of micro welders that tends to melt the metallic parts you are welding. Once they melt at the micro-levels, they immediately cool down and hold both metals in place. This whole procedure hardly takes a few milliseconds to get completed.
Different types of Micro Welding
Micro welders bring their work together in four different ways. So we can say that there are four different types of micro welding that we will discuss in the upcoming lines.
Types of micro welding
- Tig micro-welding
- Micro-laser welding
- Micro resistance welding
- Flash micro-welding
Tig Micro welding
In this micro welding procedure, a small pen-sized device is usually used to bring work towards completion. This pen completely works on an inert tungsten gas. Typically, welders opt for this welding procedure when working on high-density alloys. As minimal to no residual stress is produced as a result of micro tig welding, it is preferred by most micro welders.
Another plus point associated with this type of welding is that it stands on top in terms of integrity.
Micro laser welding
This technique of micro welding is wholly dependent on laser and doesn’t involve using any inert gas or anything else. If you intend to do deep piercing or deeper welds with great integrity, then there is nothing better than opting for this technique. As no residual gas is produced, this method is mainly used in hospital equipment, electronics, and automobiles.
Micro Resistance welding
Clasping the metallic parts together and then applying a considerable amount of current to them is used in this type of micro welding. Electrodes are rolled over the thin sheets of metals to be welded, and they become fused under the action of heat and pressure.
The step-by-step technique used for micro resistance welding
First of all, you have to clean the metal surfaces and the electrodes. Clamp the metal sheets together and place copper electrodes around either side. When you feel like everything is in place, pass a considerable amount of current through electrodes and wait for the heat generated to melt the metals; once these metals have time to cool down while in the clamped position, they will get attached.
Flash Micro welding
High pressure is used to join joints together in a clean manner. Both metal parts are pressed together at a specific temperature. As no intermediate product is used, this kind of welding is cost-effective and can be used in multiple fields. Commonly it is preferred to be used by goldsmiths and silver smiths to create beautiful and thin jewelry.
What are the typical applications of Micro welding?
You will come to see micro welding in almost every field of life. Whether it’s about electronics, automobiles, or light bulbs in every appliance, micro welding plays its part in some ways. Here are some of the commonly seen uses of micro welding:
- It is used in many fields of electronics to produce electrically conductive connections.
- Semiconductors and conductors are welded using micro welding.
- Gold and aluminum wires are welded using micro-welding
- Small electric motors and coils are welded to create fully working pieces of machinery
- Tungsten, molybdenum, and other alloys like nickel and cobalt are used to make lamps and lights. All of these alloys are welded using micro welding techniques.
- In multiple sensor technologies, micro welding is the first choice.
- Heat-sensitive areas are also welded using micro welding.
- Honeycomb welding is done using micro-welding
- Motors connections, Sensors, battery tabs, and hermetic sealing are also the processes in which you will come across micro welding.
Frequently Asked Questions
What type of micro welding is the safest?
TIG welding is the most effective and safest micro welding method. According to professional welders, a nozzle is installed at the front of the welding pen or around the tungsten electrode. By doing so, the inert gas produced will not go into the atmosphere; thus atmosphere remains safe with this type of micro welding.
What are the safety measures for micro welding?
No matter how delicate micro welding is, you must remember that harmful effects are always there. So, it’s your responsibility to take good care of yourself and your surroundings. Here are the safety measures for micro welding.
● Don’t look at the welding arch directly. It will harm your eyes. So always prefer wearing welding glasses.
● Take a face shield and wear gloves while working.
● It is recommended to wear a welders helmet.
● Don’t touch the electrode tip directly.
● Beware of touching the weld pool. It may burn your hand.
What thickness metal is micro welding ideal for?
The word micro itself says that this welding method is meant for welding thin and delicate metal. Typically, metals and alloys from 0.0003 to 5mm are welded using micro welding techniques.
Micro welding is a delicate process that gives multiple opportunities to engineers and welders to produce newer appliances. By doing so, they are making people’s lives easier and effortless. So, if you are also a welder, you can use this technique well. But remember that if you are not an expert, don’t throw your head into it because you are least likely to get desired results. First, get the expertise and then start working.