ASSIGNMENT-4 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

1. A. Explain the working principle of ERW (electric resistance welding). Explain the
working stages of spot welding. And explain why melting occurs in the middle of the
two plates to be joined.
Electric resistance welding using the principle of connecting the metal surface in the form
of sheet, and the blunt connection in the form of reduced overlap with one another using
the electrode. Then their electrical resistance is generated from electric current flowed. The
electrical resistance of the current makes the surface becomes hot and melted. In electrical
resistance welding, electrodes made of copper because copper properties very fulfilling the
criteria desired electrode. The nature of them that copper has a thermal conductivity and
high electrical, have a good deformation resistance, not easily contaminated workpiece,
and the price is cheap. In electrical resistance welding, there are three important variables,
such as: Electric resistivity, Electrode pressure, and Current and Time.
Working stage of spot welding can be explained in the figure below:

Navigate and bring electrode on the metal surface and apply a little pressure on the
surface.

Second stage occurs by applying an electric current to the electrodes so as to make

the surface becomes hot and melted.

Third stage is to release previously given electric current and electrodes were left
in place so that the material can be cooled. Melting occurs in the middle of these
two plates are connected because of the electric current flowing from the surface
down to the middle of the plate, so that the melt plate while welding.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-4 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

B. Describe the effect of current, time, and pressure on the electrical resistance welds.

Effect of current against the result of electrical resistance welding

Current is a parameter that has a major role in the current heat input because it has
a vital role in the electrical resistance welding. This current determines the speed
of the provision of heat and when the density is too high or excessive will cause the
expulsion of metal that have an impact on the formation of voids and cracks.

Effect of time against the result of electrical resistance welding

o Squeeze time
A time when the emphasis begins until the current is flow
o Weld time
A time when the current flowing in the workpiece.
o Hold time
A time in which the electrodes are still being held pressing the workpiece
with currents that are not flowing anymore.
o Off time
A period of time lasting until the end of time the next press.
Time has a greater influence on this electric resistance welding. Time is a control
parameter of the heat input. Time has a great effect on the shear strength welds.

Effect of pressure against the result of electrical resistance welding

Increased pressure of electrode causes a decrease in resistance contact. The function
of the pressure electrode itself plays a role in giving forging. The forging can then
produce a deposit with a smooth grain.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-4 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

2. Explain the working principle of spot welding with using the schematic drawings and
give the formula of heat input needed for joining the material by spot welding process.
Two overlapping sheets are connected using the principle of local melting caused by
concentrated flow between the cylindrical electrodes. Current concentration is determined
by extensive contact between the electrode and the workpiece.
Below are the mechanisms of spot welding process:

Two cylindrical electrodes placed on the surface of the workpiece connection and
the workpiece to be spliced.

Heat generation from the provision of resistance combined with the pressure that
will result in spot welding.

Heat will result in the formation of nuggets on the surface of the connection of two
workpieces. Generally, the diameter of the nugget is 6-10 mm.

Current produced ranged between 3000-40000 A.

Welding time is usually about 0.6 and 0.8 seconds.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-4 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

Melting occurs in the middle of the two plates are connected due to the spot welding is
expected on the surface of the electrical resistance between the material world (r3) while
the electrical resistivity of the material to be welded to the electrode should be as small as
possible (r1 and r5) so that the heat generated melts the part the middle of the plate are
connected. In accordance with equation (1):

3. Explain the difference between flash and upset welding through drawing the
schematic pictures.

Flash welding
Flash welding is used to connect a material that has the same cross section, wherein
the weld (weld) is produced in the entire cross section
of the contact without filler metal (filler metal).

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-4 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

Upset welding

The differences between flash welding and upset welding:

Both actually have the same arrangement. However, the main difference lies in the
mechanism used to generate the movement.

Flash welding is usually applied to connect the components with the same cross
section from end to end.

Upset welding is usually applied to connect the wire or rod with a small crosssectional area as well as for connecting pipes.

Flash welding machine has a larger capacity than the upset welding. But both can
be executed by using the same machine.

4. A. Explain the work cycle of seam welding with the schematic drawings of the cycle.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-4 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

Working schematic of seam welding:

Steel sheets overlapping, connected using a round and rotating electrode on the
outskirts of the steel. Electrodes will suppress the sheet steel.

The electrode generate heat resistance that will produce oval nuggets, lined in
accordance with the speed of the electrode.

There will be connecting to the nugget area.

Current along the line given by the split electrode rollers.

B. Explain the advantages and limitations of welding resistance welding process.

Advantages
o Brief joining for light weight metals.
o Brief joining for forging products and large size casting products.
o The result is tidier because it only needs high heat resistance to melt the
metals.

Disadvantages
o The equipment is expensive
o It needs high maintenance
o High short duration current loads

5. Which kind of material that has good weldability by using the spot welding process
for Cu, Al, and Steel.

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-4 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

The order of the material that has good weldability is steel, aluminum, and copper. This is
because steel has a fairly high electrical resistance and low thermal conductivity (52 W /
mK) compared to copper electrodes, which makes the welding process becomes much
easier. Then aluminum, aluminum has a value of electrical resistance and thermal
conductivity (109 W / mK) are approaching a copper (385 W / mK) but its melting point
is lower than copper, the welding process is still possible to use higher current.

6. A. In manufacturing of ERW pipes, give the reason why the high frequency currents
is generally used and what is role of frequency to produce the pipeline.
In the manufacture of ERW steel pipe used high-frequency currents due to concentrated on
the surface to be joined by two probes that make light contact with the connection part, the
required current is smaller and also smaller electrical contacts. By increasing the frequency
of the applied current up to 450 Hz and increasing the voltage of the unit into tens,
developed a process called high-frequency resistance welding (HFRW). The role of the
frequency of the pipe connection is made light contact between the probes with connection
parts so that the required current is smaller as well as electrical contacts.
B. Explain the advantages and limitations of the high frequency resistance welding.

Advantages
o Produce welds with narrow HAZ regions
o High welding speed and low energy consumption
o Can be used to weld the pipe which the wall is very thin
o Can be customized with a lot of metal
o Minimize oxidation
o High efficiency

Disadvantages
o Care should be taken to avoid radiation
o Less economical for small products
o Danger of high-frequency currents

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-4 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

7. Explain the working principle of projection welding, and their advantages and
limitations.

The working principle of the projection welding is a modification of the electric resistance
welding. The mechanism is to provide current concentration and pressure of the electrode
on the workpiece area. However, in the initial preparation to note that the current flow
centered on a specific contact point.

Advantages
o Produce results more neat welds due to the flow of current and focused
electrodes
o High welding speed
o Adaptable to high-speed automation production

Disadvantages
o Lap joint cause weight gain
o Connection and fatigue have low strength
o Equipment is more expensive than arc welding
o Errors welds difficult to repair

8. Explain the requirements of the weld quality of spot welding and explain this by
analyzing the size of weld nugget and the properties of tensile shear test results.
The requirements of quality of welding with spot welding analyzed from nugget size and
tensile shear test results are as follows:

METALLURGY AND MATERIALS ENGINEERING

ASSIGNMENT-4 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

Nugget size
Size nuggets of melted metal is associated with an area of contact between the
workpiece and the electrode, which in this case is also influenced by the
concentration of the current extensive contact. Diameter of the nugget as a
condition of the quality of the welding spot welding is 6-10 mm.

Result of pull shear stress test

Shear strength nuggets generally should be sufficient to ensure that when a
connection is broken then the rated voltage up to break up occurs on the sheet
around the nugget. The important thing to note is that spot welding strength can be
obtained through mechanical tests such as shear strength and cross section test.
Indicators are often used to determine the toughness of welds, especially on a hard
material that has a high afford is the ratio between the cross section strength (ft)
and shear strength (fs). When the ratio of fs / ft approaching one, welds can be said
to be resilient while the ratio of fs / ft is close to zero, brittle welds.

9. Give the schematic drawing picture (design of electron tongs) for joining two plates
by spot welding with (a) different electrical resistivity of materials (e.g. copper & steel
plates) and (b) different plate thickness (t & 2t)

(a)

METALLURGY AND MATERIALS ENGINEERING

(b)

ASSIGNMENT-4 ENMT610029 WELDING

ANDARADHI NARARYA/1206291992

10. Describe the weldability of zinc coated of steel (galvanized steel) welded by resistant
spot welding process.
For welding of zinc coated steel, required higher currents. This is due to the presence of
Zn coating layer on the steel surface. Zn coating must be melted before we continue on
steel joints. Melting point owned Zn lower than steel. So that during the welding process,
Zn combined with steel will reduce the resistivity. Therefore we need a higher current to
weld these zinc coated steel.

METALLURGY AND MATERIALS ENGINEERING

10