Manufacturing
Process I
Resistance Welding
Process
(Spot , Seam, Projection & Flash
Butt Welding)
Resistance Welding
Heat is obtained from the resistance of the work to the
flow of electric current in a circuit of which the work is
a part with the application of pressure.
No filler metal is needed
(2) pressure
Heat
H I2 R T
H = heat generated (J), I = Current (A), R = Resistance
(), T =Time (s)
Current:
H I2
Heat increase with increase of current
Low current does not give proper fusion.
High current heated the entire thickness of the work
metal between the electrodes to the plastic state; the
entire thickness reaches the fusion temperature and the
electrodes themselves deeply into the metal.
Resistance
R1: Resistance of the workpieces
R2: Contact resistance between the electrodes and
the work.
R3: Resistance between the faying surfaces of the
two metal pieces to be welded.
R2
R1
R3
Time, T
Four definite segments or periods of timing during one
welding cycle
1. Squeeze time
2. Weld time
3. Hold time
4. Off time
Squeeze time: Time between the initial application of
the electrode pressure on the work and the initial
application of current to make the weld. At the end of
the squeeze time, the welding current is applied.
Weld time: During this period the welding current flows
through the circuit, i.e., it enters from one electrode,
passes through the work pieces and goes out from the
second electrode.
Hold time: Time during which force acts at the point of
welding after the last impulse of welding current ceases.
The electrode pressure is maintained until the metal has
somewhat cooled.
Off time: Interval from the end of the hold time to the
beginning of the squeeze time for the next
(resistance) welding cycle.
1. Current.
2. Electrode pressure.
3. Welding time.
4. Human element.
5. Welding machine characteristics.
6. Type and condition of machines.
7. Conditions of electrodes and arms.
8. Condition of the material and surfaces of
material.
9. Throat depth.
10. Throat height.
Spot Welding
Resistance welding process in which overlapping sheets
are joined by local fusion at one or more spots by the
heat generated, by resistance to the flow of electric
current through workpieces that are held together
under force by two electrodes, one above and the other
below the two overlapping sheets.
Procedure
Step 1: Electrodes are brought together against the
overlapping work pieces and pressure applied so that the
surfaces of the two workpieces under the electrodes come
in physical contact after breaking any unwanted film
existing on the workpieces.
Sho
w
Side
Sho
w
Sid
Insulat
e ion
Sho
w
Sid
e
Spot Weldable
Metals
Ferrous Metals
(i) Low carbon steel (mild
steel)
(ii) Hardenable steels
(iii) High speed steel
(iv) Stainless steels
(v) Coated steel sheets
Non-ferrous Metals
(i)Aluminium
(ii) Aluminium Magnesium Alloys
(iii) Aluminium Manganese
Alloys
(iv) Copper
(v) Nickel, Nickel alloys and
Monel Metal
Seam Welding
Heat obtained from resistance to electric current (flow)
through the work parts held together under pressure by
electrodes.
Resulting weld is a series of overlapping resistance-spot
welds made progressively along a joint by rotating the
circular electrodes.
Principle of Operation
Different
types
seams produced
Sheet metal
parts
of
Electrode
wheel
Individual weld
nuggets
Overlapping weld
nuggets
Metals Welded
(i) Low-carbon, high carbon and low-alloy steels.
(ii) Stainless and many coated steels.
(iii) Aluminium and its alloys.
(iv) Nickel and its alloys.
(v) Magnesium alloys.
Flash Butt
Welding
Flash
produced
during the
process.
Probably,
flash
welding
process was developed from
resistance butt welding by
accident in attempts to increase
the capacity of the butt welding
machines by raising the voltage
and
applying
pressure
intermittently.
Heat
obtained
from
resistance to electric current
between the two surfaces, and
by the application of pressure
after heating is substantially
completed.
Principle of Operation
(ii)
Movable
platen
is
brought towards the one
gripped in the stationary
platen until the two come in
light
contact.
Welding
current
(with
voltage
sufficiently high) is turned
on, flashing is established.
Movable platen keeps move
with a constant speed. The
end of the workpieces burn
off
as
gradually
the
temperature
raised into
welding temperature.
(iii) Pressure of the moving
clamp is quickly increased
to forge the parts together
and expel the molten metal
later.
Weldable metal:
(i) Low carbon steels.
(ii) Medium strength and high strength low
alloy steels.
(iii) Tool steels.
(iv) Stainless steels.
(v) Aluminium alloys (with thickness greater
than 1.25 mm).
(vi) Copper alloys (with high zinc content).
(vii) Magnesium alloys.
(viii) Molybdenum alloys.
(ix) Nickel alloys.
(x) Titanium alloys.
(i) ManyAdvantages
dissimilar metals
different
melting
ofwith
Flash
Welding
temperatures can be flash welded.
(ii) Flash welding offers strength factors up to 100%.
(iii) Generally no special preparation of the weld
surface is required.
(iv) Flash welding can be used for the welding of
those highly alloyed steels which cannot be
welded satisfactorily by any other process.
This is because, in flash welding, under correctly
controlled conditions, the heating is not only even but
extremely local, so that the cooling stresses are
maintained at a minimum; this avoids hardening and
cracking in highly alloyed steels.
(v) The process is cheap, i.e., the cost of current per
weld is small.
(vi) Flash welding is faster than many other
methods.
(vii) Flash welding gives a smaller upset.
(i) The
most undesirable feature
of flash
welding is
Disadvantages
of Flash
Welding
the flashing operation during which it is impossible to
protect the welding machine and the surrounding area
from these particles, which can burn into slide way
bearings, insulation etc. This necessitates more
frequent maintenance.
(ii) The process presents a considerable fire
hazard. Operators need be protected from flying
particles.
(iii) Concentricity and straightness of
workpieces during welding is often difficult to
maintain.
(iv) Metal is lost during flashing and upsetting.
(v) Shape of the workpieces to be flash welded
should be similar.
(vi) It is generally not recommended for welding zinc
and its alloys, cast iron, lead and its alloys.
Applications of Flash
Welding
(i) Flash welding
is applied primarily in the butt
welding of metal sheets, tubing, bars, rods, forgings,
fittings etc.
(ii) Flash welding finds applications in automotive
and aircraft products, household appliances,
refrigerators and farm implements.
(iii) The process is also used for welding the band
saw blades into continuous loops, and joining of tool
steel drill, tap and reamer bodies to low carbon steel
and alloy steel shanks.
(iv) Flash welding is used to produce assemblies
that otherwise would require more costly forgings or
castings.
Projection Welding
Heat obtained from resistance to electric current flow
through the work parts held together under pressure by
electrodes.
Resulting welds are localized at predetermined points
by projections, embossments or intersections.
Projection welding
is similar
to spot
Principle
of Operation
welding
except
that
(i) The electrodes, instead of being tips as
in spot welding, are flat and relatively
large in surface area. Electrodes are
cooled as in spot welding.
(ii) Since a number of welds are made at
each operation, both the electrical power
(kVA) and mechanical pressure must be
correspondingly greater, as compared with
a spot welder.
Success of projection welding depends on
the surface preparation of the work-pieces
to be welded.
Projections, small deformations that will
touch the surface of the material to be
welded are formed on the weld areas by
Metals Welded
(i) Low carbon (0.20% C max) steels
(ii) Coated metals such as galvanized steel, terne
plate, tin plate, etc.
(iii) Naval brass, Monel (Ni-Cu) alloys
(iv) Stainless steel
(v) Titanium alloys
pplications
tomobiles
ss production work- refrigerator, condenser, crossed wire welding etc.
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