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LECTURE 3

HIGH FREQUENCY WELDING

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HIGH FREQUENCY WELDING - LECTURE 2

GENERAL DESCRIPTION
High Frequency Welding, HFW ; the joint
produce by the heat generated from electrical resistance of the work to high frequency current and application of upsetting force. Type of HFW
High Frequency Resistance Welding HFRW High Frequency Induction welding - HFIW
3/23/2013 HIGH FREQUENCY WELDING - LECTURE 2

GENERAL DESCRIPTION
HFRW Physically electrical contacts to
work piece to produce high frequency current. HFIW The current is induce in the work piece by coupling with an external induction coil

3/23/2013

HIGH FREQUENCY WELDING - LECTURE 2

GENERAL DESCRIPTION
HFIW

3/23/2013

HIGH FREQUENCY WELDING - LECTURE 2

GENERAL DESCRIPTION
HFRW

3/23/2013

HIGH FREQUENCY WELDING - LECTURE 2

High Frequency Induction Welding on Steel bar


3/23/2013 HIGH FREQUENCY WELDING - LECTURE 2

GENERAL DESCRIPTION
Factors need to be considered in HFW
Welding speed very high Maximum speed limited by mechanical consideration of mechanical handling, forming and cutting Minimum speed limited by material properties and weld quality requirement

3/23/2013

HIGH FREQUENCY WELDING - LECTURE 2

HISTORY
1940s development of HFIW butt end welding
for pipes and tubes. 1949 First HFIW system for continuous forge welding of the longitudinal seam welding for small tube was developed. 1952 Thomas Crawford tested on continuous induction welding of the longitudinal seam of various tubes. 1952 WC Rudd and R.Stanton invented a 400kHz for welding a large verity of continuous joints.
3/23/2013 HIGH FREQUENCY WELDING - LECTURE 2

Advantages and limitation


Advantages
Very narrow HAZ Skin effect HF current flows near surface Proximity effect HF current flows along narrow controlled path. Stronger weld joint Need no PWHT High welding speed Able to weld very thin sheet 0.13mm (Foil) Applicable to all metal Minimize the oxidation, discoloration and distortion. Have a balanced three-phase power input system High efficiency machine

3/23/2013

HIGH FREQUENCY WELDING - LECTURE 2

Advantages and Limitation


Limitation
Need proper fit-up Suitable to fully automation system. Limited to used of coil, flat or tubular stock with a constant joint symmetry throughout the length of the part. Electrical Hazards need a special precaution.

3/23/2013

HIGH FREQUENCY WELDING - LECTURE 2

Fundamental of Process
HF current flows in metal conductors at the
surface of the material at relatively shallow depth (Skin Effect). The HF current path at the surface of the workpiece is controlled by nearest of its own return flow-path (Proximity Effect). Fig 20.2 page 656. The depth of penetration can be refer to Fig. 20.2 Page 655 (AWS Welding Handbook)

3/23/2013

HIGH FREQUENCY WELDING - LECTURE 2

Process Variation
HFI Welding
Tube- Seam Welding Produce continuous seam welding on tube and
pipe

3/23/2013

HIGH FREQUENCY WELDING - LECTURE 2

Process Variation
HFI Welding
Butt Welding of Hollow Pieces

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HIGH FREQUENCY WELDING - LECTURE 2

Process Variation
HFR Welding
Continuous Seam Welding

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HIGH FREQUENCY WELDING - LECTURE 2

Process Variation
HFR Welding
Finite Welding (To be continue)

3/23/2013

HIGH FREQUENCY WELDING - LECTURE 2