Welded Bellows
Welded Bellows represent another major manufacturing method for metal bellows, with distinct characteristics and a wide range of critical applications.
Here is a detailed overview of Welded Bellows applications.
What are Welded Bellows?
Welded bellows are constructed by welding a series of individually stamped metal diaphragms (or discs) together at their inner and outer diameters. This process creates a flexible, accordion-like assembly.
Manufacturing Process Brief:
- Stamping: Individual diaphragm rings are precision stamped from thin metal sheet.
- Alignment: The diaphragms are stacked alternately (inner diameter to inner diameter, outer diameter to outer diameter).
- Welding: The stacked diaphragms are welded at their contact points, typically using precision techniques like electron beam welding or micro-plasma welding.
- Finishing: The end fittings (flanges or hubs) are welded on.
Core Characteristics & Advantages
The welded construction gives these bellows unique performance attributes:
Large Stroke/Displacement:
- Advantage: Can achieve a much greater compression and extension length compared to hydraulically formed bellows of the same diameter.
- Why: The displacement is distributed over many individually thin diaphragms, each contributing a small amount of flex.
High Precision & Complex Profiles:
- Advantage: Can be manufactured in a very wide range of diameters (from a few mm to several meters) and with custom profiles that are difficult or impossible to achieve with hydroforming.
- Why: The individual diaphragms can be stamped into nearly any shape.
Low Spring Rate (High Flexibility):
- Advantage: Requires very low axial force to compress or extend.
- Why: The thin diaphragms and their welded joints offer minimal resistance to axial movement.
Excellent Performance in Vacuum and High Temperatures:
- Advantage: The all-metal construction and precise welding make them ideal for maintaining integrity in vacuum systems and resisting high temperatures.
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