Rivet-Free Metal Structured Packing Welding Machine
Rivet-free MFDC welding system for metal structured packing. No holes, no rivets, no corrosion points.
Creates a metallurgical fusion joint with ≈30% higher structural strength and fully automated 1-second weld cycle. Suitable for stainless steel packing production.
Description
Rivet-Free Metal Structured Packing Welding Machine
Next-Generation MFDC Fusion Welding Technology for Metal Structured Packing
🔍 If your packing is still riveted, the joint is your weakest point.
Compare it — not conceptually, but physically.
Send your packing model (125–700) and we will provide welded test samples, inspection photos, and lifecycle performance data for direct evaluation.
🔶 Advantages of MFDC Structured Packing Welding
-
Rivet-Free Connection — No holes, no rivets, no crevice/edge corrosion points.
-
≈1-Second Weld Cycle — Automated positioning + MFDC output for repeatable joints.
-
≈30% Higher Structural Strength — Fusion joint resists vibration & thermal cycling.
-
Full Traceability — Current / Pressure / Time automatically recorded per weld.
-
Ultra-Clean Assembly — No punching chips, no rivet debris inside the column.
Development Background of Rivet-Free Metal Structured Packing Welding-Why We Re-engineered the Joint
For decades, metal structured packing modules were assembled with punched holes and rivets. That was practical in early designs, but long-term operation in high temperature, solvent-rich media, or under pulse-jet cleaning exposed fundamental weaknesses:
-
• Corrosion initiates at hole edges and crevice gaps
-
• Rivets loosen under thermal cycling and vibration
-
• Stress concentration around holes reduces fatigue life
-
• Metal debris from punching/riveting risks column contamination
-
• Output quality depends on operator skill and manual alignment
Modern separation systems require longer runtimes, higher reliability, and fewer shutdowns. Incremental fixes to riveting no longer suffice.
👉 This drove the development of MFDC Fusion Welding — a joining method designed not just to speed assembly, but to eliminate the very failure mechanisms inherent to riveted structures.
Why Riveted Metal Structured Packing Is Reaching Its Limits
Limitations of Riveted Structured Packing
-
❌ Holes create stress risers and corrosion origins
-
❌ Rivet heads can loosen and distort module geometry
-
❌ Manual alignment → variable quality and rework
-
❌ Debris and burrs → cleanliness risks in columns
MFDC Fusion Welding – What Changes in Structured Packing
-
✅ Metallurgical bond (no holes, no mechanical fasteners)
-
✅ Smooth flow surface, no protrusions or gaps
-
✅ Higher fatigue & flexural strength (~30% typical improvement)
-
✅ Automated, repeatable cycle with digital records
What MFDC Fusion Welding Changes
MFDC (Medium Frequency Direct Current) resistance welding fuses the corrugated sheets into a continuous metallurgical joint, eliminating holes, rivets, and surface discontinuities:
• No holes → No corrosion origins
• No rivets → No loosening or geometry shift
• Smooth surface → Improved wetting and flow uniformity
• Higher structural stability under thermal cycling and vibration
How the Rivet-Free Metal Structured Packing Welding Machine Works
1️⃣ Stacking — Corrugated sheets are placed one up / one down.
2️⃣ Alignment — Servo positioning locates the weld coordinates to ±0.5 mm.
3️⃣ MFDC Fusion — High-frequency controlled current produces solid-state metallurgical bonding, not melting-through or deformation.
4️⃣ Metallurgical Bond — Surfaces integrate into one continuous body.
5️⃣ Data Traceability — Welding parameters (current / pressure / time) are automatically recorded for QA and audit tracking.
Welding Performance and Structural Integrity Improvements
| Item | Riveted Connection | MFDC Fusion Welding |
| Joint Type | Hole + Rivet (Mechanical) | Metallurgical Fusion (No Holes) |
| Corrosion Risk | ✔ High (starts at hole edges) | ✘ None (no crevices / no gap) |
| Structural Strength | Normal, loosens over time | ≈30% Higher, no loosening |
| Cleanliness | Metal debris from punching | No debris, clean assembly |
| Cycle Time | 10–15 min / module (manual) | ≈1 sec / weld (automatic) |
| Traceability | None | Current / Pressure / Time recorded |
Technical Specifications – Metal Structured Packing Welding Machine
| Item | Specification |
| Effective Welding Envelope | 2000 × 450 × 200 mm |
| Welding Process | MFDC Metallurgical Fusion Resistance Welding |
| Weld Cycle Time | ≈1 second per weld |
| Positioning Accuracy | ±0.5 mm (servo-controlled) |
| Power Rating | 45 kVA |
| Input Voltage | 380V / 50Hz / 3-Phase |
| Air Supply | ≥ 0.6 MPa |
| Electrode Cooling | Water-cooled Tungsten-Copper (WCu) |
| Data Logging | Current / Pressure / Time / Weld Count (Fully Traceable) |
| Machine Dimensions | 4300 × 1550 × 2100 mm |
Metal Structured Packing Welding Performance Validation
-
✅ No corrosion marks in 6–24-month runtime inspections
-
✅ No weld-fatigue failures under pulse cleaning & thermal cycling
-
✅ Stable geometry after prolonged service
-
✅ Zero debris → No contamination risk in columns
Applications & Industry Use Cases for Metal Structured Packing Welding
-
Petrochemical distillation columns
-
Absorption & desorption towers
-
Refining & solvent recovery systems
-
Desulfurization / decarbonization units
-
High-purity fine chemical and pharmaceutical separation
Request Samples / Technical Demonstration
We provide:
✔ Welded structured packing sample pieces
✔ Cross-sectional weld analysis
✔ Strength & fatigue comparison data
✔ Online technical review session
→ Send your packing model & material grade. We configure the weld pattern accordingly.