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Certification : CE. RoHS
Delivery Time : 25-45 working days
Supply Ability : 10 sets per month
Keyword : Steel Pipe Butt Welding Machine
power (kw) : 40-200KVA
Brand Name : Xingwei
Packaging Details : Wooden box
input voltage : 220 V, 380 V, 480V
Place of Origin : Sichuan, China
Price : $2,800 / set
MOQ : 1 set
Product name : Pneumatic Flash Butt Welder for Square Pipe Copper Wire and Steel Bar
MOQ : 1 Set
After Warranty Service : Video technical support, Online support and Spare parts
Payment Terms : D/A,L/C,D/P,Western Union,T/T
Application : Steel Pneumatic Butt Welding Machine 25 Mm Diamete
warranty : 12 Months
Weld method : Butt Welding
After-sales Service Provided : Free spare parts, Field installation, commissioning and training
Welding square tubes end-to-end, joining copper wires up to 8mm, or butt-welding steel rebar on a construction site — this pneumatic flash butt welder handles the profile shapes and conductive materials that standard butt welders cannot. CrZrCu electrodes maintain hardness at welding temperature, dual V-guides keep profiles aligned, and the upset mechanism produces joints with strength approaching the base metal.
✓ Handles Square Pipes, Copper Wire (Up to 8mm), Steel Rebar and Profiles
✓ CrZrCu Electrodes — High-Temperature Hardness for Copper and Non-Ferrous
✓ Dual V-Guide Alignment — Keeps Profiles Centered During Flashing and Upset
✓ 480V Option Available for Heavy Industrial Power Supply
Standard flash butt welders are designed for flat strips with rectangular cross-sections. This machine handles the geometry challenges of square tubes, round bars, profiled sections and copper wire. The dual V-guide system centers non-flat workpieces. The Chromium Zirconium Copper electrodes maintain hardness when welding highly conductive materials like copper that draw massive current. And the pneumatic upset system delivers the controlled forging force needed for consistent joint consolidation across irregular profiles.
Square tubes, round bars and shaped profiles require precise axial alignment for a quality butt weld. The hardened, wear-resistant dual V-guides center the workpiece ends and maintain their relative position throughout the flashing and upset sequence. Without this alignment system, profiled sections tend to shift under clamping force, producing misaligned joints with reduced strength and poor appearance. The V-guide design accommodates different profile shapes without requiring custom fixturing for each geometry.
Copper and other highly conductive non-ferrous metals present a challenge for resistance welding electrodes: the same high current that welds the workpiece also heats the electrode. Standard copper electrodes soften at sustained high temperature, losing shape and contact pressure. Chromium Zirconium Copper alloy electrodes maintain hardness and conductivity at welding temperature, extending service life and ensuring stable current transmission when welding copper wire and copper-alloy profiles.
The high-performance pneumatic system delivers massive, stable clamping force that prevents workpiece slippage during the flashing phase and applies precisely controlled upset force during forging. This is critical for profile welding where the clamping must grip non-flat surfaces securely. The adjustable upset force allows the operator to match forging pressure to the material and cross-section, ensuring proper joint consolidation whether welding thin-wall square tube or solid steel rebar.
Seven power ratings from 40 to 200 KVA cover the full range from thin copper wire to heavy steel bar. Standard 380V and 220V configurations serve most facilities, while the 480V option supports heavy industrial power systems common in North American and Middle Eastern plants. The simplified mechanical architecture with fewer moving parts than automated systems means the machine is reliable in field and construction-site conditions where maintenance access may be limited.
| Parameter | DN-40 | DN-63 | D(T)N-80 | D(T)N-100 | D(T)N-125 | D(T)N-160 | D(T)N-200 |
|---|---|---|---|---|---|---|---|
| Rated Power at 50% (KVA) | 40 | 63 | 80 | 100 | 125 | 160 | 200 |
| Primary Voltage (V) | 380 (220V / 480V Available) | ||||||
| Secondary Voltage (V) | 5.2 | 6.7 | 7.9 | 8.3 | 8.6 | 9.1 | 10.6 |
| Max. Short Circuit (KA) | 14 | 15 | 16 | 18 | 20 | 28 | 34 |
| Max. Weld Power (KVA) | 62 | 86 | 170 | 280 | 300 | 330 | 410 |
| Throat Depth (mm) | 400 | 450 | |||||
| Max. Electrode Force (N) | 6000 | 10000 | 12000 | ||||
| Working Stroke (mm) | 20 | 30 | 40 | 50 | |||
| Cooling Water (L/min) | 6 | 8 | 10 | ||||
| Electrode Tip (mm) | 13x45 | 16x45 | 20x45 | ||||
| Arms (mm) | 50x150 | 80x220 | |||||
| Max. Capacity A3 Steel (mm) | 2.5+2.5 | 3+3 | 4+4 | 4.5+4.5 | 5+5 | 6+6 | |
| Copper Wire Capacity | Up to 8mm | ||||||
Construction sites and structural fabrication shops use flash butt welding to join steel rebar end-to-end for continuous reinforcement runs, and to join square tube sections for frames and structural members. The pneumatic clamping grips round and square profiles securely, and the upset forging produces joints with full cross-sectional strength. The simplified machine architecture is rugged enough for construction-site conditions where precision automated equipment would be impractical.
Copper wire and busbar joining in electrical manufacturing requires welds that maintain conductivity across the joint. The CrZrCu electrodes are specifically designed for the high current and thermal demands of welding highly conductive copper. The flash butt process creates a forged joint with density and conductivity approaching the parent copper, without the resistance discontinuity that solder or mechanical connectors introduce. Suitable for copper wire up to 8mm diameter and copper-alloy conductor profiles.
General metal fabrication shops that work with bar stock, tubing and profiled sections use the butt welder for end-to-end joining when longer lengths are needed than available stock. The dual V-guide alignment system handles round, square and irregular profiles without custom fixturing. Carbon steel, alloy steel and non-ferrous metals are all within the machine''s capability with appropriate parameter settings.
Manufacturers of metal gates, fences, railings and architectural metalwork use the butt welder to join tube and bar sections where continuous lengths exceed available stock or where custom configurations require end joining. The flash butt process produces clean, strong joints that require minimal post-weld grinding before finishing, preserving production speed in high-volume architectural metalwork operations.
Xinwei Welding Technology Co., Ltd. operates an 18,000 square meter manufacturing facility with a dedicated R&D team of over 20 engineers. ISO 9001, CE and RoHS certified. Serving customers in more than 30 countries worldwide.
Our pneumatic flash butt welding machines are tested on customer-representative profile and wire samples before shipment. The CrZrCu electrode system, dual V-guide alignment mechanism and pneumatic clamping circuit are calibrated for reliable operation across the full range of supported materials including carbon steel, alloy steel, copper and non-ferrous metals.
| Feature | Your Welding Benefit |
|---|---|
| Dual V-Guide Alignment | Centers square tubes, round bars and profiles for precise butt joints |
| CrZrCu Alloy Electrodes | Maintains hardness when welding copper and high-conductivity metals |
| Pneumatic Upset System | Controlled forging force for consistent joint consolidation |
| 480V Power Option | Compatible with North American and Middle Eastern industrial power |
| Copper Wire Up to 8mm | Handles highly conductive materials that challenge standard welders |
| 12-Month Warranty | Online support, spare parts and optional on-site training |
Send us samples of your profile, pipe, bar or wire material with dimensions and grade. Our engineers will run test welds and provide joint strength data and cross-section analysis — free of charge.
Send your material samples for a free flash butt welding test
✓ Joint Tensile and Bend Testing on Customer Material Samples
✓ Weld Cross-Section Inspection for Joint Consolidation Quality
✓ CrZrCu Electrode Hardness and Conductivity Verification
✓ Dual V-Guide Alignment Accuracy Calibration
✓ ISO 9001:2015 Certified Quality Management System
Q: Can this machine really weld copper wire?
Yes. Copper''s high electrical conductivity means standard electrodes heat up quickly and lose hardness when welding copper workpieces. The CrZrCu (Chromium Zirconium Copper) electrodes used in this machine maintain their hardness and conductivity at elevated temperatures, enabling reliable copper wire butt welding up to 8mm diameter. The flash-upset process creates a forged joint with conductivity approaching the parent copper, making it suitable for electrical applications where joint resistance matters.
Q: How does the dual V-guide handle square tubes differently from flat strips?
Square tubes and profiled sections tend to rotate or shift under clamping force in standard flat-plate butt welders. The dual V-guide system uses angled guide surfaces that self-center the workpiece regardless of its external geometry. This ensures the two ends remain axially aligned during the flashing and upset sequence, producing straight, strong butt joints on square tubes, rectangular sections and other non-flat profiles.
Q: Is this machine suitable for construction site use?
Yes. The simplified mechanical architecture with pneumatic actuation and fewer moving parts than fully automated systems makes the machine practical for construction and field applications. The 480V power option supports the heavy industrial electrical supply common on large construction projects. The rugged frame and wear-resistant dual V-guides are designed for the less controlled environment of site work compared to factory production lines.
Q: What is the difference between this and the strip butt welder?
The strip butt welders (DN series for bandsaw blades) are optimized for flat strips with rectangular cross-sections up to 50mm width. This profile butt welder is designed for non-flat geometries — square tubes, round bars, copper wire, and profiled sections. The dual V-guide alignment and CrZrCu electrodes are specific to the challenges of profile welding. If you are welding flat strips and blades, the strip welder is the right choice. If you are welding tubes, bars, profiles or copper wire, this machine is the correct tool.
Tell us your material type, profile shape, cross-section dimensions and production volume. Our engineers will recommend the optimal DN model and can perform sample welds on your material.
12-Month Warranty | Free Sample Test | Factory Direct from Xinwei
















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Pneumatic Flash Butt Welder for Square Pipe Copper Wire and Steel Bar Images |