04 Resistance

LAS TAHANAN LISTRIK
(Electric Resistance Welding)

Dr. Ir. Winarto, M .Sc.
Departemen Metalurgi & Materials

Fakultas Teknik Universitas Indonesia
D r. Ir. Winarto, M.Sc.
Resistance Welding Processes
Resistance Spot Welding (RSW)

Resistance Seam Welding (RSEW)
Projection Welding (PW)
High Frequency and Induction RSEW
Flash Welding (FW)
High Freq. & Induction Upset Welding (UW)
Dr. Ir. Winarto, M.Sc.
Spot, seam and projection welding.

Pencairan logam terjadi pada permukaan oleh panas yang
berasal dari tahanan listrik logam tersebut yang di beri arus.
Pada proses ini digunakan gaya baik sebelum, selama dan
setelah arus diberikan.
Ciri utama proses ini adalah arus yang diberikan sangat singkat
oleh karena itu diperlukan arus yang besar untuk dapat
menimbulkan panas yang dibutuhkan untuk menyambung. Jadi
proses ini merupakan proses yang dapat menghasilkan panas
yangsangat cepat.
Q = I2 R t
Energy ERW
Spot, seam dan projection welding.

Faktor yang diperlukan:
Harus ada kontak fisik antara elektroda yang membawa
arus dengan benda kerja
Tekanan untuk menahan benda kerja dalam kontak
3 variabel penting dalam teknik pengelasan resistansi listrik;

Tahanan listrik
Tekanan elektroda
Arus dan waktu
Spot, seam dan projection welding.

Tahanan listrik sistem pengelasan resistansi listrik terdiri atas
Tahanan listrik elektroda
Tahanan listrik antara permukaan elektroda dan material yang di las
Tahanan listrik material yang di las
Tahanan listrik antar permukaan material yang di las
Kesetimbangan Panas; Terjadi bila kedalaman fusi (penetrasi)
pada kedua pelat yang di las sama.
Faktor yang mempengaruhinya a.l;
1. Konduktifitas termal dan listrik material yang di las
2. Geometri bagian yang di las
3. Konduktifitas termal dan listrik elektroda
4. Geometri elektroda
HEAT BALANCE
Resistance Spot Welding
Uses heat generated by resistive heating

Total heat proportional to square of current
Total heat proportional to time
Total heat proportional to resistance
Pressure
Keeps molten weld metal from being expelled
Provides follow up during cooling contraction
Clean surfaces best

Although less resistance, less variation in resistance
makes welds reproducible
Effect of Pressure on Resistance

Small variation in
resistance due to
change in pressure
Large variation in
resistance due to
change in pressure
Source: Lindberg, Roy A., Processes and Materials of Manufacture 4th Ed, Prentice Hall, Upper
Saddle River, 1990 pg. 751, Fig.17-3
Peralatan Spot Welding
Resistance Welders
Spot Welder
Seam Welder
Source: Cary, H. B., Modern Welding Technology, 5th ed., Prentice Hall, Upper Saddle
River, 2002, pg. 243 Fig. 8-5 and pg. 251, Fig. 8-20
Skematis Mesin Spot Welding
Resistance Spot Welding
SPOT WELDING
SPOT WELDING
d ( mm ) 5 s
Spot, seam and projection welding.

S iklus Pengelasan:
1. S queeze time
2. Weld time
3. Hold time
4. Off time
Keunggulan
Kecepatan pengelasan tinggi dan dapat dengan mudah
beradaptasi untuk otomatisasi dalam kecepatan produksi
yang tinggi.
Keterbatasan.
Sulit di perbaiki jika terjadi kesalahan pengelasan
Lap joint yang menajdi syarat berakibat penambahan berat
Peralatan lebih mahal dibandingkan dengan arc welding
Kekuatan sambungan rendah dan fatik juga rendah
Siklus Spot Welding
Mekanisme Spot Welding
(Thousands to
hundreds of
thousands of
amps)
(Hundreds to
thousands of
pounds force)
Cycles of AC
(sixtieths of a second)
Saddle River, 1990 pg. 751, Fig.17-2 Courtesy of American Machinist
Uji Mekanis
10
Kekuatan vs Parameter Las
Introduction to Resistance Seam Welding

Roll Spot Weld
Upper Electrode Wheel
Knurl or Friction
Drive Wheel
Overlapping Seam
Weld
ContinuousSeam
Weld
Workpiece
Throat
Lower Electrode Wheel
Welding Handbook, Volume

D r. Ir. Winarto,
2, p.553,
M.Sc. AWS]
11
Lap Seam Weld

Electrodes
Overlapping
Weld
Nuggets
Travel
Front view
Side View
[Ref erence: Welding Handbook, Volume 2, p.554, AWS]

Peralatan Seam Welding
12
Prinsip Kerja Seam Welding
Prinsip Kerja Seam Welding
13
Seam Welding
OverlappingSpots
Intermittent Spots
SPOT WELD FUEL TANKS

.
R/L 5
Braket Fuel Unit

Patch fuel cock
(2
)
(8
)
R.
L( 2 )
Clip Wire throttle
(1)
( 7 ~ 12 )
R. L
(2)
14
SEAM WELD FUEL TANKS

.
Plate tank
Bottom Comp
Star
Awal
Fuel Tank Assy

Projection Welding
Projection localizes heat, collapses during weld.

Useful for attaching fasteners to larger components.
15
Prinsip Kerja Projection Welding
Flash, upset and percussion welding

Digunakan untuk menyambung material yang
memiliki penampang yang sama dimana weld di
hasilkan pada seluruh penampang yang kontak
tanpa filler metal.
Ketiga jenis di atas dibedakan atas metoda pemanasan
dan waktu penerapan penekanan
16
Flash Welding
Digunakan untuk menyambung material yang memiliki penampang yang
sama dimana lasan (weld)
di hasilkan pada seluruh
penampang yang kontak
tanpa logam pengisi (filler
metal).
Flash Welding
Arc parts until ends heated

to forging temperature.
Forge parts together.

Flash must be removed.
17
Flash v.s Upset
Flash and upset welding machines are similar in construct ion.

The major difference is the motion of the movable platen
during welding and the mechanisms used to impart the motion.
Flash weld-fig is generally preferred for joining components
of equal cross section end-to-end.
Upset welding is normally used to weld wire, rod, or bar of
small cross section and to join the seam continuously in pipe
or tubing.
Flash welding machines are generally of much larger capacity
than upset welding machines. However, both of these
processes can be performed on the same type of machine. The
metals that are to be joined serve as electrodes.
Percussion Welding
This process uses heat from an arc produced by a
rapid discharge of electrical energy to join metals.
Pressure is applied progressively during or
immediately following the electrical discharge.
The process is similar to flash and upset welding.
Two types of welding machines are used in
percussion welding: magnetic and capacitor
discharge.
A unit generally consists of a modified press-type
resistance welding machine with specially designed
transform, controls, and tooling.
18
High-frequency welding
Weld dihasilkan oleh panas dari tahanan listrik benda
kerja yang diberi arus ber-frekwensi tinggi .
Ada dua jenis

HFRW ( high frequency resistance welding)
HFIW (high frequency induction welding atau
induction resistance welding)
High-Frequency Resistance Welding

Weld dihasilkan oleh panas dari tahanan listrik benda
kerja yang diberi arus ber-frekwensi tinggi .
Ada dua jenis

HFRW ( high frequency resistance welding)
HFIW (high frequency induction welding atau
induction resistance welding)
19
Electric Resistance Butt-Seam Welding
High Frequency Resistance Welding
20
High Frequency Welding
Skin effect current attracted to

itself to minimize potential.
High Frequency Induction Welding
21
Resistance Tube Welding (ERW)
W. Stanley, Resistance Welding

McGraw-Hill, 1950
The Making Shaping & Treating of Steel,
DUSS
r. Ir.Corp,
Winarto,
1964 M.Sc.
22
The Making Shaping & Treating of Steel,
DUSS
r. Ir.Corp,
Winarto,
1964 M.Sc.
Current Flow in a conductor as a

function of Frequency
DC
60 HZ AC
KiloHertz AC
High Frequency
23
High Frequency
Induction Welding
Appreciating Hig-Frequency Welding

Welding Journal, July 1996
Metals Handbook, Vol 6
D r. Ir. Winarto,
M.Sc.
ASM
International, 1983
24
Impeder Inside the

Core Promotes
Path ADC
Linnert, Welding Metallurgy
D r. Ir. Winarto,
AWS, M.Sc.
1994

Applications (CONT.)
HF
HF
Strip Butt
HF
T-Joint
HF
Spiral Tube Fin

Spiral Tube
[Ref erence: Welding Handbook, Volume 2, p.653, DAWS]
r. Ir. Winarto, M.Sc.
25

Applications (CONT.)
HF
Induction
Coil
Projection Seam
HF
HF
Pipe Butt
Bar Butt

Advantages of High-Frequency
Welding
Produce welds with very narrow heat-affected zones
High welding speed and low-power consumption
Able to weld very thin wall tubes
Adaptable to many metals
Minimize oxidation and discoloration as well as

distortion
High efficiency
26
Limitations of High-Frequency
Welding
Special care must be taken to avoid radiation

interference in the plants vicinity
Uneconomical for products required in small

quantities
Need the proper fit-up
Hazards of high-frequency current

Some Products of High-Frequency Welding
27
Mash Seam Weld

Slightly Lapped
Sheets
Wide, Flat
Electrodes
Weld Nuggets
Before welding
After Welding
Effect of S heet Overlap on

Mash Lap Joint properties
Resistance Welder Manufacturers

Association Bulletin # 21
28
Effect of Electrode Force

on Mash S eam Weld

Metal Finish Seam Weld

Finish
Side
Chamfered
Electrode
Broad, Flat
Electrode
Before Welding
Flash
After Welding
29
Effect of Weld Current

and Electrode Force on
Finish S eam Welds
Resistance Welder Manufacturers Association Bulletin # 24
Effect of Current on Metal

Finish S eam Weld

30
Recommended
S heet
Positioning
Resistance Welder Manufacturers Association Bulletin # 24
ASM Handbook Vol6, 1993
31
Porter, Galvanizing and welding structural steel,

Metal Construction, Nov 1983
ASM Handbook Vol6, 1993
32
Resistance Welding Processes

Advantages
Fast joining of light gauge metals
Fast joining of large forgings or castings
Excellent way to add fasteners to products
Limitations
High short duration current loads
Relatively expensive equipment requires high
volume production to justify investment
Metals to be welded
33
Weldability
W : Mampu las baik ; L: Mampu las terbatas; N: Mampu las buruk
Weldability
No.
1.
2
3
4
Metal
Thermal
Cond.
(W/m-K)
Electrical
Resistivity
(Ohms-cm)
Melting
Point (C)
Steel (1020)
Aluminum
Zinc
Copper
52
190
112
385
17.4E-6
5.0E-6
5.9E-6
1.7E-6
1500
620
420
1085
34
W = weldability, R = Resistivity, and F = the melting

temperature of the metal in degrees C, and Kt = the relative
thermal conductivity with copper equal to 1.00.
If weldability (W) is below 0.25, it is a poor rating.
If W is between 0.25 and 0.75, weldability becomes fair.
Between 0.75 and 2.0, weldability is good.
Above 2.0 weldability is excellent.
In this formula, mild steel would have a weldability rating of
over 10. Aluminum has a weldability factor of from 1 to 2
depending on the alloy and these are considered having a good
weldability rating. Copper and certain brasses have a low
weldability factor and are known to be very difficult to weld
Thank You
Any Questions?
35

04 Resistance

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

04 Resistance

Diunggah oleh

Hak Cipta:

Format Tersedia

LAS TAHANAN LISTRIK

(Electric Resistance Welding)

Departemen Metalurgi & Materials

Resistance Welding Processes

Resistance Spot Welding (RSW)

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc.

Spot, seam and projection welding.

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc.

Spot, seam dan projection welding.

3 variabel penting dalam teknik pengelasan resistansi listrik;

D r. Ir. Winarto, M.Sc.

Spot, seam dan projection welding.

Dr. Ir. Winarto, M.Sc.

D r. Ir. Winarto, M.Sc.

Resistance Spot Welding

Uses heat generated by resistive heating

Clean surfaces best

Dr. Ir. Winarto, M.Sc.

Effect of Pressure on Resistance

D r. Ir. Winarto, M.Sc.

Peralatan Spot Welding

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc.

Skematis Mesin Spot Welding

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc.

Resistance Spot Welding

D r. Ir. Winarto, M.Sc.

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc.

Spot, seam and projection welding.

Dr. Ir. Winarto, M.Sc.

Siklus Spot Welding

D r. Ir. Winarto, M.Sc.

Mekanisme Spot Welding

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc.

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc.

Kekuatan vs Parameter Las

D r. Ir. Winarto, M.Sc.

Introduction to Resistance Seam Welding

Dr. Ir. Winarto, M.Sc.

Welding Handbook, Volume

Lap Seam Weld

[Ref erence: Welding Handbook, Volume 2, p.554, AWS]

Peralatan Seam Welding

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc.

Prinsip Kerja Seam Welding

D r. Ir. Winarto, M.Sc.

Prinsip Kerja Seam Welding

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc.

SPOT WELD FUEL TANKS

Braket Fuel Unit

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc.

SEAM WELD FUEL TANKS

Fuel Tank Assy

Projection localizes heat, collapses during weld.

Dr. Ir. Winarto, M.Sc.