Electric Resistance Welding
Electric Resistance Welding
Electric Resistance Welding
0. INTRODUCTION:
Electric resistance welding is an important and widely applied
non-fusion welding process. This write-up covers the basic principles
of various resistance welding processes, effects of the parameters,
applications of these processes and the equipments needed for them.
When a high electric current is passed through a small area of
two butting metal surfaces, heat is generated at the interface.
Heat generated H = I2 X R2 X t
Where
I - current passed
R - resistance of the interface
t - time of application of current.
When the interface attains a coalescent state, a huge pressure
is applied to the heated interface to form the weld joint. Sheets,
tubes, wires or even rods can be welded using various resistance
welding processes. The parameters viz., current, time of application
of current, pressure, duration of pressure applied and electrodes
depend on the process used, materials to be welded, thickness of the
job and also the application to which the welded joint is put in.
1.0 RESISTANCE WELDINGPROCESSES.
The following five are the main types of resistance welding,
1. Spot welding
2. Seam welding
3. Proiection weldina
4. Upset butt welding
5. Flash butt welding
Weld expulsion
Cavitation
Weld cracking
Reduced mechanical properties
Electrode embedment in the surface
iv.
v.
vi.
If the spots in seam welding are not overlapping, then that process
is termed as roller spot welding. Other seam welding processes are
lap seam welding, butt seam welding, mesh seam welding and high
frequency seam welding.
(ii)
in
rotatingapparatus
electro
has
GROUP B - REFRACTORY..
Class 10, 1 1, 12 - Cu & WClass 13 - W 1
Class 14 - Mo For welding of Cu ofbrass.
2.2.8.3. SPOT AND PROJECTIONWELDING ELECTRODES.
Four main parts of the electrodes are:i. Face
ii. Shank or kody
iii. Means of attachment to the electrodeholder
iv. Provision for cooling.
Spot welding electrodes can have pointed,dome, fiat, eccentric,
truncated or radiusface. The shank may be tapered or R maybe
straight having threads for attachment.Internal cooling may be
provided orimmersion cooling, flooding or a wraparound copper tube
cooling may beadopted.
The holders may be of ejector or non-ejector type and straight,
universal or off-set models. The electrodes should beused with the
prescribed holders andadopters in order that a good weld isobtained.
Electrode
material
dressing,cooling,
cieanliness
of
the
engagementsection, proper alignment and propermachine settings
are also important. TheFig.15 shows a few types of spot
weldingelectrodes. Projection weialing electrodesusually makecontact
wfththeworkonflat
surfaces that must always be larger thanthe base diameter of the
projection.Generally flat face spot welding electrodesare used. In
cross-wire welding,rectangular bar stock is used.
The projection welding electrodes haveinternal water cooling and
replaceableinserts is used.
2.2.8.4. SEAM WELDINGELECTKC)DF-5..
of
themanufacturers
of
resistance