Professional Documents
Culture Documents
Seam Welding
Lesson Objectives
When you finish this lesson you will
understand:
The various forms of seam welding
Nugget formation mechanisms
Quality testing of Seam Welds
Learning Activities
1. View Slides;
2. Read Notes,
3. Listen to lecture
4. Do on-line
workbook
5. Homework
Keywords
Roll Spot Weld, Overlapping Seam Weld, Continuous Seam Weld,
Lap Seam Weld, Mash Seam Weld, Metal Finish Seam Weld, Butt
Seam Weld, Foil Butt Seam Weld, Projection Seam Weld, Weld
Current-Pulse Time, Welding Speed, Overlap Distance, Nugget
Formation, Seam Weldability, Pillow Test
Overlapping Seam
Weld
Continuous Seam
Weld
Workpiece
Lower Electrode Wheel
Throat
[Reference: Welding Handbook,
Volume 2, p.553, AWS]
Electrodes
Travel
Front view
Side View
@ 6 Cycle Heat
75%
66%
60%
54%
50%
46% Heat
Welding Speed
Improper
selection of
Parameters
Leads to
Porosity in
Weld
Wide, Flat
Electrodes
Weld Nuggets
Before welding
After Welding
Chamfered
Electrode
Broad, Flat
Electrode
Before Welding
Flash
After Welding
Recommended
Sheet
Positioning
Stage 1 Takes 1 - 4
cycles, Increased
resistance due to
increased temp
outweighs reduction in
resistance due to better
surface contact through
asperity softening and
surface oxide
breakdown
Peak occurs earlier
with thinner
materials
Stage 2 Drop in
resistance because of
current shunting into
the mushy and solid
state bonded region
Stage 3 Instability in
current path, nugget
approaching a steady
state growth mode
Stage 1
Nugget Initiates
Stage 2
Nugget Moves
Toward Exit
Stage 3
Approaching
Steady State
Actual Data
(effect of Speed)
2 m/min
4 m/mim
At Lower Speeds
At Higher Speed
Increased Current
Ahead of nugget
Less Heat Extracted
through Electrode
Larger thru Sheet
Nugget Growth
Waddell, Mechanism of weld formation,
Welding and Metal Fabrication, Aug 1995
Through Sheet
Nugget Growth
2 m/min
6 m/min
16 m/min
Waddell, Mechanism of weld formation,
Welding and Metal Fabrication, Aug 1995
Enter
Exit
Increased Speed
Nugget
Type A
HAZ
Length of Heat Zone
Increased Speed
HAZ
Nugget
Type B
Unstable
Transition Pattern
Nugget
Type C
HAZ
Sheet Thickness
0.7 mm
1.2 mm
2.0 mm
Welding Speed
2 m/min
10 m/min
At High Speeds,
Current Flow and
Heat Generation
Extended to Sheet
Surface
Exit
End
Enter
End
Transverse
Longitudinal
Increased
Electrode
Force
Contact
Area
Increased Indentation
Irregular nuggets
irregular pulses that does not give time for heat flow
ASM Handbook Vol6, 1993
Dynamic Resistance
Continuous
Seam Weld
Time
Attorre, The influence of welding parameters on formation of solute bands,
Welding In the World, Vol37, 1996
Pulsed Current
Current
Expulsion or
Overheating
Higher Current
Non-Continuous
Seam
Uncoated Steel
Hot-Dipped Galvanized
AWS Welding Handbook , Vol 4, 1998
Exit
Entry
Expulsion
Weld
Coating
High Speed
Current Density
As travel speed increases, more material is presented to the rolls per half cycle of current
thus reaching a limit to the current density in the part
Expulsion
With increased travel speed, complete nugget formation is delayed until the weld forms
outside the pressure influence of the rolls (see next slide) and expulsion is easier.
Seam Weld
Quality Tests
Tensile Tests
Pillow Tests
6 x 6 inch Pillow
6 x 10 inch Pillow
Seam Welding