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Module 1 - Processes Review
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Process Review
Lesson ObjectivesWhen you finish this lesson you will understand:• The basic principles of the most common resistance welding processes
Learning Activities1. Review the contents
of WE6022. Look up Keywords3. View Slides; 4. Read Notes, 5. Listen to lecture6. Do on-line
workbook
KeywordsResistance Spot Weld, Resistance Projection Weld, Resistance Seam Weld, Flash Weld, Upset Butt Weld, Electric Resistance Weld, High Frequency Weld, Electro-Brazing
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Introduction to Resistance Spot Welding
Top ElectrodeWater
WeldNugget
Bottom Electrode
Resistance
Dis
tan
ce
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Typical Equipment of Resistance Spot Welding
(a) (b)[Reference: Welding Process Slides, The Welding Institute]
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Process Operation of Resistance Spot Welding
[Reference: Welding Process Slides, The Welding Institute]
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Advantages of Resistance Spot Welding
Adaptability for Automation in High-Rate
Production of Sheet Metal Assemblies
High Speed
Economical
Dimensional Accuracy
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Limitations of Resistance Spot Welding
Difficulty for maintenance or repair Adds weight and material cost to the product, compared with
a butt joint
Generally have higher cost than most arc welding equipment
Produces unfavorable line power demands
Low tensile and fatigue strength The full strength of the sheet cannot prevail across a spot
welded joint
Eccentric loading condition
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Turn to the person sitting next to you and discuss (1 min.):• The heating in resistance spot welding is related to the resistance by the equation H=I2Rt. The resistance can be both bulk and surface resistance. If we change from welding steel to welding aluminum what changes in resistance do you expect?
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Introduction to Projection Welding
(a) (b) (c) (d)
[Reference: Welding Handbook, Volume 2, p.566, AWS]
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Advantages of Projection Welding
• A number of welds can be made simultaneously in one welding cycle of the machine
• Less overlap and closer weld spacing are possible• 1 < Thickness ratio < 6• Smaller in size than spot welding• Better appearance on the side without projection• Less electrode wear than spot welding• Oil, rust, scale, and coatings are less of a problem
than spot welding
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Limitations of Projection Welding
• Require an additional operation to form projections
• With multiple welds, require accurate control of projection height and precise alignment of the welding dies
• Thickness limitation for sheet metals
• Require higher capacity equipment than spot welding
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Examples of Various Projection Designs
(a)(b)
(c) (d) (e)
[Reference: Welding Handbook, Volume 2, p.562, AWS]
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Examples of Various Projection Designs (CONT.)
(f) (g) (h)
(i) (j)[Reference: Welding Handbook, Volume 2, p.562, AWS]
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Turn to the person sitting next to you and discuss (1 min.):• As projections collapse, the welding electrode and head must move rapidly to keep up with the projection collapse. What things might hinder the heads rapid movement? What would you do to design a more rapid moving head?
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Introduction to Resistance Seam Welding
Upper Electrode Wheel
Workpiece
Lower Electrode Wheel
Throat
Knurl or FrictionDrive Wheel
Roll Spot Weld
Overlapping SeamWeld
Continuous SeamWeld
[Reference: Welding Handbook, Volume 2, p.553, AWS]
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Mash Seam WeldSlightly LappedSheets Wide, Flat
Electrodes
Weld Nuggets
Before welding After Welding
[Reference: Welding Handbook, Volume 2, p.554, AWS]
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Introduction to Flash Welding
[Reference: Welding Process Slides, The Welding Institute]
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Basic Steps in Flash Welding
(a) (c)
(b) (d)
Electrodes
[Reference: Welding Handbook, Volume 2, p.583, AWS]
Position and Clamp the Parts
Apply Flashing Voltageand Start Platen Motion
Flash
Upset and Terminate Current
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Equipment Example of Flash Welding
[Reference: Welding Process Slides, The Welding Institute]
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Advantages of Flash Welding
• Flexible cross sectioned shapes
• Flexible positioning for similar cross section parts
• Impurities can be removed during upset acts• Faying surface preparation is not critical except for large
parts
• Can weld rings of various cross sections
• Narrower heat-affected zones than those of upset welds
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Limitations of Flash Welding
• Produce unbalance on three-phase primary power lines
• The ejected molten metal particles present a fire hazard
• Require special equipment for removal of flash metal• Difficult alignment for workpieces with small cross
sections
• Require almost identical cross section parts
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Common Types of Flash Welds
Cross Section After Welding
Transformer
Fixed Platen Movable Platen
Dies
Axially Aligned Weld
[Reference: Welding Handbook, Volume 2, p.589, AWS]
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Common Types of Flash Welds (CONT.)
Cross Section After WeldingFixed Platen Movable Platen
Transformer
Miter Weld
[Reference: Welding Handbook, Volume 2, p.589, AWS]
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Common Types of Flash Welds (CONT.)
Cross Section After WeldingFixed Platen Movable Platen
Transformer
Ring Weld
[Reference: Welding Handbook, Volume 2, p.589, AWS]
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Turn to the person sitting next to you and discuss (1 min.):• In flash welding of steel, the iron burns to iron oxide during flashing and removes oxygen from the flashing interface. The free energy of formation of iron oxides at 1500K are about –40 kcal/gram-atom of oxygen. The free energy of formation of titanium oxides at 1500K is about –90 kcal/gram-atom oxygen. What effect do you suppose this would have on the flash welding operation?
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Introduction to Upset Welding
Finished Upset Weld
Heated Zone
To Welding Transformer
Clamping Die
UpsettingForce
Movable Part
Clamping Die
Stationary Part
[Reference: Welding Handbook, Volume 2, p.598, AWS]
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Typical Mill Forms and Products of Upset Welding
[Reference: Welding Handbook, Volume 2, p.600, AWS]
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Resistance Tube Welding (ERW)
W. Stanley, Resistance WeldingMcGraw-Hill, 1950
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High Frequency Welding Applications
[Reference: Welding Handbook, Volume 2, p.653, AWS]
Tube Butt Seam Tube Butt Seam Tube Mash Seam
HF
HF
HFInduction Coil
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High Frequency Welding Applications (CONT.)
Strip Butt T-Joint
Spiral Tube
Spiral Tube Fin
HFHF
HFHF
[Reference: Welding Handbook, Volume 2, p.653, AWS]
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High Frequency Welding Applications (CONT.)
Projection Seam
Pipe Butt Bar Butt
HF
HF
HF
InductionCoil
[Reference: Welding Handbook, Volume 2, p.653, AWS]
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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
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Limitations of High-Frequency Welding
• Special care must be taken to avoid radiation interference
in the plant’s vicinity
• Uneconomical for products required in small quantities
• Need the proper fit-up
• Hazards of high-frequency current
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Some Products of High-Frequency Welding
[Reference: Welding Handbook, Volume 2, p.665, AWS]
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Turn to the person sitting next to you and discuss (1 min.):• If you were going to make tubing or pipe materials what might be the criteria when you would select ERW over High Frequency Welding?
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Electro-brazing
W. Stanley, Resistance WeldingMcGraw-Hill, 1950
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