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)

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 1

 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

D r. Ir. Winarto, M.Sc.

Energy ERW

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 2

 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

D r. Ir. Winarto, M.Sc.

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
D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 3

 HEAT BALANCE

D r. Ir. Winarto, M.Sc.

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

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 4

 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
D r. Ir. Winarto, M.Sc.

Peralatan Spot Welding

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 5

 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
D r. Ir. Winarto, M.Sc.

Skematis Mesin Spot Welding

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 6

 Resistance Spot Welding

Source: Lindberg, Roy A., Processes and Materials of Manufacture 4th Ed, Prentice Hall, Upper
Saddle River, 1990 pg. 751, Fig.17-2
D r. Ir. Winarto, M.Sc.

SPOT WELDING

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 7

 SPOT WELDING

d ( mm ) 5 s

D r. Ir. Winarto, M.Sc.

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
D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 8

 Siklus Spot Welding

D r. Ir. Winarto, M.Sc.

Mekanisme Spot Welding

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 9

 (Thousands to (Hundreds to
hundreds of thousands of
thousands of pounds force)
amps)

Cycles of AC
(sixtieths of a second)

Source: Lindberg, Roy A., Processes and Materials of Manufacture 4th Ed, Prentice Hall, Upper
Saddle River, 1990 pg. 751, Fig.17-2 Courtesy of American Machinist D r. Ir. Winarto, M.Sc.

Uji Mekanis

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 10

 Kekuatan vs Parameter Las

D r. Ir. Winarto, M.Sc.

Introduction to Resistance Seam Welding

Roll Spot Weld

Upper Electrode Wheel

Knurl or Friction Overlapping Seam

Drive Wheel Weld

ContinuousSeam
Weld

Workpiece
Throat

Lower Electrode Wheel

Welding Handbook, Volume 2, p.553,
D r. Ir. Winarto, M.Sc. AWS]

Dr. Ir. Winarto, M.Sc. 11

 Lap Seam Weld

Electrodes Overlapping
Weld
Nuggets

Travel

Front view Side View

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

D r. Ir. Winarto, M.Sc.

Peralatan Seam Welding

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 12

 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. 13

 Seam Welding

OverlappingSpots

Intermittent Spots
Source: Lindberg, Roy A., Processes and Materials of Manufacture 4th Ed, Prentice Hall, Upper
Saddle River, 1990 pg. 757, Fig.17-7
D r. Ir. Winarto, M.Sc.

SPOT WELD FUEL TANKS

.

R/L 5
Braket Fuel Unit

Patch fuel cock (2

)
(8
)

R.
L( 2 )

Clip Wire throttle ( 7 ~ 12 ) R. L

(1) (2)

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 14

 SEAM WELD FUEL TANKS

Plate tank
Bottom Comp
Star
Awal

Fuel Tank Assy

D r. Ir. Winarto, M.Sc.

Projection Welding

Projection localizes heat, collapses during weld.

Useful for attaching fasteners to larger components.
Source: Lindberg, Roy A., Processes and Materials of Manufacture 4th Ed, Prentice Hall, Upper
Saddle River, 1990 pg. 758, Fig.17-8
D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 15

 Prinsip Kerja Projection Welding

D r. Ir. Winarto, M.Sc.

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

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 16

 Flash Welding
Digunakan untuk menyam-
bung material yang me-
miliki penampang yang
sama dimana lasan (weld)
di hasilkan pada seluruh
penampang yang kontak
tanpa logam pengisi (filler
metal).

D r. Ir. Winarto, M.Sc.

Flash Welding

Arc parts until ends heated Forge parts together.

to forging temperature. Flash must be removed.
Source: Lindberg, Roy A., Processes and Materials of Manufacture 4th Ed, Prentice Hall, Upper
Saddle River, 1990 pg. 760, Fig.17-10
D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 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.

D r. Ir. Winarto, M.Sc.

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.

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 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)

D r. Ir. Winarto, M.Sc.

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)

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 19

 Electric Resistance Butt-Seam Welding

High Frequency Resistance Welding

Dr. Ir. Winarto, M.Sc. 20

 High Frequency Welding

Skin effect current attracted to

itself to minimize potential.
Source: Lindberg, Roy A., Processes and Materials of Manufacture 4th Ed, Prentice Hall, Upper
Saddle River, 1990 pg. 758, Fig.17-8
D r. Ir. Winarto, M.Sc.

High Frequency Induction Welding

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 21

 Resistance Tube Welding (ERW)

W. Stanley, Resistance Welding

McGraw-Hill, 1950 D r. Ir. Winarto, M.Sc.

The Making Shaping & Treating of Steel,

DUSS
r. Ir.Corp,
Winarto,
1964 M.Sc.

Dr. Ir. Winarto, 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

KiloHertz AC
DC 60 HZ AC
High Frequency

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 23

 High Frequency
Induction Welding

Appreciating Hig-Frequency Welding

Welding Journal, July 1996 D r. Ir. Winarto, M.Sc.

Metals Handbook, Vol 6

D r. Ir. Winarto, M.Sc.
ASM International, 1983

Dr. Ir. Winarto, M.Sc. 24

 Impeder Inside the
Core Promotes
Path ADC

Linnert, Welding Metallurgy

D r. Ir. Winarto,
AWS, M.Sc.
1994

High Frequency Welding

Applications (CONT.)
HF
HF

Strip Butt T-Joint

HF
HF

Spiral Tube Fin

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

Dr. Ir. Winarto, M.Sc. 25

 High Frequency Welding
Applications (CONT.)

HF

Induction Projection Seam HF

Coil

HF
Pipe Butt Bar Butt
[Ref erence: Welding Handbook, Volume 2, p.653, AWS]
D r. Ir. Winarto, M.Sc.

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
D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 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

D r. Ir. Winarto, M.Sc.

Some Products of High-Frequency Welding

[Ref erence: Welding Handbook, Volume 2, p.665, AWS]

D r. Ir. Winarto, M.Sc.

Dr. Ir. Winarto, M.Sc. 27

 Mash Seam Weld
Slightly Lapped
Sheets Wide, Flat
Electrodes

Weld Nuggets

Before welding After Welding

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

Effect of S heet Overlap on

Mash Lap Joint properties

Resistance Welder Manufacturers

Association Bulletin # 21

Dr. Ir. Winarto, M.Sc. 28

 Effect of Electrode Force
on Mash S eam Weld

Resistance Welder Manufacturers

Association Bulletin # 21

Metal Finish Seam Weld

Finish
Chamfered Side
Electrode

Flash
Broad, Flat
Electrode

Before Welding After Welding

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

Dr. Ir. Winarto, M.Sc. 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

Resistance Welder Manufacturers

Association Bulletin # 21

Dr. Ir. Winarto, M.Sc. 30

 Recommended
S heet
Positioning

Resistance Welder Manufacturers Association Bulletin # 24

ASM Handbook Vol6, 1993

Dr. Ir. Winarto, M.Sc. 31

 Porter, Galvanizing and welding structural steel,
Metal Construction, Nov 1983

ASM Handbook Vol6, 1993

Dr. Ir. Winarto, M.Sc. 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

Dr. Ir. Winarto, M.Sc. 33

 Weldability

W : Mampu las baik ; L: Mampu las terbatas; N: Mampu las buruk

Weldability

No. Metal Thermal Electrical Melting

Cond. Resistivity Point (C)
(W/m-K) (Ohms-cm)
1. Steel (1020) 52 17.4E-6 1500
2 Aluminum 190 5.0E-6 620
3 Zinc 112 5.9E-6 420
4 Copper 385 1.7E-6 1085

Dr. Ir. Winarto, M.Sc. 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?

Dr. Ir. Winarto, M.Sc. 35