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    Lecture 6 - RSW - FSW

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    Lecture 6 - RSW - FSW

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    Lecture 6 - RSW_FSW

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    12 views25 pages

    Lecture 6 - RSW - FSW

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    kashika10084

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    Casting, Forming and Welding

    ME31201
    Section 2
    Lecture 6

    VNM Vamsi, Sushanta Panda, Siddharth Tamang


    Resistance Welding
    Resistance welding processes employ a combination of pressure and
    heat to produce a weld between the workpieces. Resistance heating
    occurs as electrical welding current flows through the workpieces.
    The heat generated by the current flow may be expressed as follows:
    Q = P t = I2R t
    where
    Q = Heat generated, J
    I = Current, A
    R = Resistance, ohms (); and
    t = Duration of current flow, s.
    Resistance Spot Welding (RSW)
    Water Cooled
    Electrodes

    Work Piece

    Water Cooled

    Electrodes

    Force
    Advantages
    • It is a rapid process (<1 second per weld)
    • Ease of automation (flexible process)
    • No Requirement of welding consumables (i.e., no issues of
    piece-cost, inventory, additional weight or recycling
    difficulties)
    The resistance that is important in resistance spot welding is
    composed of the following factors:
    1. Contact resistance between the electrodes and the work,
    2. Contact resistance between the workpieces,
    3. Body resistance of the workpieces, and
    4. Resistance of the electrodes.
    a

    x
    y

    1 - Resistance of the Electrode (a)


    2 – Resistance between electrode (a) and sheet (x)
    3 - Resistance of the sheet (x)
    4 – Resistance between sheet (x) and sheet (y)
    5 - Resistance of the sheet (y)
    6 - Resistance between electrode (b) and sheet (y)
    7 - Resistance of the Electrode (b)
    Squeeze Hold Off
    Weld time time time
    time
    Electrode Force

    Weld Current

    Start
    Nugget formation and heat dissipation into the surrounding base
    metal and electrodes during resistance spot welding 15
    Resistance Seam Weld- application
    Problem
    An RSW operation is used to make a series of spot welds between two pieces of aluminum, each
    2.0 mm thick. The unit melting energy for aluminum = 2.90 J/mm3. Welding current = 6,000 amps,
    and time duration = 0.15 sec. Assume that the resistance between the aluminium sheets = 75 micro-
    ohms. The resulting weld nugget measures 5.0 mm in diameter by 2.5 mm thick.
    How much of the total energy generated is used to form the weld nugget?
    Friction welding
    Friction Welding Friction Stir Welding
    Friction Stir Welding
    • Def: Friction Stir Welding is a welding process in which the
    metals transforms from a solid state into a "plastic-like"
    state, and then mechanically stirs the materials together
    under pressure to form a welded joint.
    • It overcomes many of the problems associated with
    traditional joining techniques
    • FSW is a solid state process which produces welds of high
    quality in difficult to weld materials. Coalescence is achieved
    by frictional heat combined with pressure
    • It is used for manufacturing light weight transport structures
    Friction stir welding (FSW)

    Shoulder
    Plunging of tool.
    Similar to drilling operation
    Plunge
    Pin out
    Heat generated = Friction +Plastic deformation of workpiece
    Frictional heat Exit hole
    Side View
    Traverse speed of tool to perform welding
    A.S. Vt

    Work piece Top View

    R.S.
    26
    Process parameters: Rotational speed, Weld speed, Tilt angle, Plunge depth

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