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By N.K. Chawla
Mobile +91 9810191280 E-mail :nkchawla@kaizenmetal.com
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IMPORTANCE OF WELDING
Welding is the most efficient way to join metals. Only way to join two or more pieces of metals to make them act as one piece. Welding is the most economical method to permanently join metal parts. All metals can be joined by one welding process or another. There is saying if it is metal, weld it and it is true. Look around, almost everything made of metal is welded, the worlds tallest building, moon rocket engines, nuclear reactors, home appliances and automobile, barely start the list. The use of welding is still increasing.
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Historical Development of Welding..contd. Resistance welding processes were developed, including spot welding, seam welding, projection welding, and flash butt welding. Elihu Thompson originated resistance welding. His patents began in 1885. He originated a company, the Thompson Electric Welding Company and developed the different resistance welding processes that time in 1900.
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Welding Defined
Welding as defined by American Welding Society Welding is defined as a joining process that produces coalescence (Fusion) of materials by heating them to the welding temperature, with or without the application of pressure or by the application of the pressure alone, and with or without the use of filler metal. In less technical language; A weld is made when separate pieces of material to be joined combine and form one piece when heated to a temperature high enough to cause softening or melting and flow together. Pressure may or may not be used to force the pieces together. Filler material is added when needed to form a 14 completed weld in their joint.
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Resistance Welding
Resistance welding (RW): a group of welding processes that produce coalescence of the faying surfaces with the heat obtained from resistance of the workpieces to the flow of the welding current in a circuit of which the workpieces are a part and by the application of pressure.
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Seam Welding
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Percussion Welding
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The high current, up to 1,00000 A. at low voltage generates sufficient heat at this resistance point so that the metal reaches a plastic stage. The force applied before, during and after the current flow 23 forges the heated parts together so that fusion will occur.
METALS WELDABLE BY THE REISTANCE WELDING PROCESS Metal Aluminiums Magnesium Inconel Nickel Brass and bronze Monel Precious metals Low carbon steel Low alloy steel High and medium carbon steel Titanium Stainless steel Weldability Weldable Weldable Weldable Weldable Weldable Weldable Variable weldable Weldable Weldable Weldable Weldable Weldable Weldability Rating 0.75-2+ 1.80 2+ 2.15 0.5-10+ 2+ 0.16-3.0 10+ 10+ 10+ 50+ 35+
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The rocker arm machines have a pivoted on rocking upper electrode arm which is actuated by either the operators physical power or by air or hydraulic power.
They are used for a wide variety of work but are restricted to 50 KVA and are used for thinner sheets.
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Squeeze time is the time between the first application of the electrode force and the first application of welding current. Weld time is the actual time the current flows. Hold time is the period during which the electrode force is applied and the welding current is shut off. Off time is the period during which the electrodes are not contacting the work pieces. The inbuilt timer on the machine controls these four different 37 steps.
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Thumb Rule for selecting spot welding parameters for low carbon steel sheets
If t =thickness of thinnest outside sheet in mm. Then required nugget diameter is = 4 x t To achieve this following weld parameters can be selected. Weld current Weld time Weld force = 9 x t KA =10 x t cycles = 200 x t kgf.
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MINIMUM WELD NUGGET DIAMETER FOR AUTOMOTIVE RESISTANCE SPOT WELDS Material Thickness (in mm) 0.38-0.62 0.63-0.87 0.88-1.13 1.14-1.38 1.39-1.64 1.65-1.89 1.90-2.14 2.15-2.52 2.53-2.91 2.92-3.29 3.30-3.67 3.68-4.05 4.06-4.22 Weld Diameter (in mm) 3.0 3.8 4.3 5.1 5.3 5.6 6.1 6.6 7.1 7.4 7.6 8.1 8.4
Avg. diameter = D+d/2 as obtained from a peel test Weld nugget diameter taken from AWS D8.7-88 SAE J-1188 Recommended Practices48 for Automotive Weld Quality Resistance Spot Welding.
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Projection welding is somewhat similar to spot welding. To make a projection weld, projections are formed on at least one of the work pieces at the points where welds are desired. The projections, small raised areas, can be any shape such as round, oval, circular, oblong or diamond. They can be formed by embossing, casting, stamping or machining.
The work pieces that have the projections are placed between plain,large area electrodes in the welding machine. The current is turned on, and pressure is applied. Since nearly all of the resistance is in the projections, most of the heating occurs at the points where welds are desired resulting in fusion of the work pieces.
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Method for peel test by pressing. Method for peel test by torque 59
Resistance Seam Welding Seam welding is similar in some way to spot welding except that the spots are spaced so close together that they actually overlap one another to make a continuous seam weld. In this process roller wheels act as electrodes. These roller type electrodes are usually copper alloy disc 10mm to 16mm thick. Both the upper and lower wheels are This process is quite powered. Pressure is applied in the common for making welds, for same manner as a press type spot flange welder. Water cooling is not making water tight provided internally and the weld area joints for tanks, and so is flooded with cooling water to keep on. 60 the electrode wheels cool.
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Thank you
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