International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com April 2015, Volume 3 Issue 4, ISSN 2349-4476

Experimental Analysis of Leakages in Seam Welding by

Controlling Seam Welding Parameters
Avishi Gupta, Dr. K. M. Moeed
Integral University, Lucknow

I. ABSTRACT
The seam welding is one of the most popular welding techniques used in industries for
leak proof welding joints. This basically uses a non-consumable welding electrode in
the form of wheel. The input parameters in seam welding plays a significant role in
deciding the weld quality, strength, cost and speed. Most of the times manufacturer
faces a problem to select optimum process parameter for a good quality weld. This
paper will present the effect of different welding parameter like heat %, cool time,
type of pass, weld time, sheet thickness, and electrode force on the leakage
percentageof seam welding in transformer radiator. These all parameter have different
effect on welding leakage. In order to analyze leakage percentage, experimental work
has been performed.
KEYWORDS – Resistance welding, Seam welding machine, CRCA steel.

II. INTRODUCTION
Resistance seam welding is widely used process for joining metal sheets in the
automobile and power industries. It is also used in the manufacturing of steel sheets in
relation to leakage tightness. In all these application leakage is not allowed and thus it
is important for reliable welding procedure to be used. The most important factor for
maintaining consistency and a good seam weld nugget formation are, the welding force,
welding current magnitude, welding speed, electrode shape and the mode of current
being supplied.
In seam welding electrode used are in the form of rollers as shone in the Fig, 1. The
electrical current is passed through the roller shaped electrode, which produces heat at
the interface of the sheet which are to be joined. A seam welding process p roduces a
series of nugget at the interface of the steel sheets. The parts to be welded are placed
between the circular electrodes, which run at a constant velocity in opposite directions
and the squeezes force is applied by these electrode. The current pr oduces a joule
heating effect at the contact of the two sheets and the weld nugget is thus formed.

264 Avishi Gupta, Dr. K. M. Moeed

 International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com April 2015, Volume 3 Issue 4, ISSN 2349-4476

III. EXPERIMENTAL DETAILS

Experiment is perform on Transformer Radiator panel. Radiator panel are form of Cold
Roll Cold Annealed sheet having thickness of 1 mm. Seam welding is used to weld lock
two sheet from its edges so as to ensure leak proof joint. Th e metal used is as Bhushan
Steel Limited product TDC No.0000296511 Grade –D used in fabrication.
GR PR HARD E.C.V Y.S. UTS E LON% %C %Mn %S %P % AL
AD ODU NESS MM KG/MM² KG/ GL-
E CT HRB/VP N/MM² MM² 50/80
N MM
D CRC 86 11.1 16.28 29.28 40.20 0.035 0.12 .0009 0.008 0.037

IV. WELDING PROCESS

Set of welding specimens are made as follows: Specimens are prepared by changing
one parameter and keeping the other parameter c onstant. Different parameters are heat
percentage, cool time, welding pressure, welding contact area etc. Specimens are taken
at heat percentage varying from 55% to 75% with an interval of 10% and at welding
contact area varying between 6mm to 10mm. while making specimen other parameter
are kept constant i.e. cool time – welding pressure 6 bar

V. WELDING EQUIPMENT
The RSW equipment employed in this investigation is a standard pneumatically
operated weld head cylinder of following specification .
S.No. Part Name Specification Make Qty
1 Pneumatic Cyl Weld Head Ø100 X STR. -100 Festo 01
Cyl
2 Weld Transformer 75 KVA Kirpekar 01
3 Weld Controller Microprocessor Kirpekar 01
Based

Electrode wheel electrodes used are manufactured at MIPALLOY, Tamil Nadu. Class 2
Copper Chromium. Specification: RWMA Class 2 Copper USN C18200

.
Fig. 2 – Seam welding electrode
VI. OBSERVATION
Following observation are observed when Heat percent increase from 55% to
75%keeping other constrain constant under leakage test of Specimen at 2 KgF pressure
under water.

S.No Heat Percent No. Of Specimens Percentage of leakage

1. 55% 20 18%
2. 60% 20 5%
3. 65% 20 5.5%
4. 70% 20 7%
5. 75% 20 12%

265 Avishi Gupta, Dr. K. M. Moeed

 International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com April 2015, Volume 3 Issue 4, ISSN 2349-4476

Table 2.Observation table for no. of leakages at different heat percent.

This can be easily interpret through graph-

Following observation are observed when electrode wheel contact area increases from
6mm to 10mm keeping other constrain constant under leakage test of specimen at 2 Kg
F pressure under water.

S.No Welding wheel contact area No. Of Specimens Percentage of leakage

1. 6 mm 20 6.00%
2. 7 mm 20 6.15%
3. 8 mm 20 6.80%
4. 9 mm 20 7.05%
5. 10 mm 20 8.00%
Table 3.Observation table for no. of leakages at different welding wheel contact
area.
This can be easily interpret through graph -

266 Avishi Gupta, Dr. K. M. Moeed

 International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com April 2015, Volume 3 Issue 4, ISSN 2349-4476

VII. Conclusion:
Optimum heat percentage require for reduced or controlled leakage in specimen i.e.
Transformer Radiator manufactured from 1 mm CRCA steel is between 60 to 65%.It is
also observed that on increasing heat percent above 75% sheet start over melti ng and
molten metal get stick on the electrode wheel.
In case of contact area, optimum area obtain is between 6mm to 7mm . this can also be
explained as:

Heat = I²Rt
Where, H = Heat generated, Joules
I = Current, Amperes
R = Resistance, Ohms
t = Time of current flow, Seconds

Now, Heat = I² (ƿL/A)t

Where, ƿ =Specific electrical resistance
L = length of the conductor, meter
A = Cross sectional area of conductor , metres²

Therefore, increase in area will decrease the resistance and hence overall heat will al so
be decreased.

VIII. REFERENCES
[1] R.K. Jain, Production Technology [Manufacturing processes, Technology and
Automation ], Khanna Publication, 17 th edition.
[2] Dr. R.S. Parmar, Welding process and Technology, Khanna Publishers, First
edition.
[3] O.P. Khanna, Welding Technology, DhanpatRai Publication, 20 th reprint 2011.
[4] Quanfeng song, Wenqi Zhang &Niels Bay, An Experimental study determines the
electrical contact resistance in resistance welding, Supplement To the welding
journal, May 2005, sponsored by the American Society and the Welding Research
Council.
[5] J.Saleem, A. Majid,K. Bertilsson, T.Carlberg, 3 Dimensional Finite Element
Simulation of Seam Welding Process,Elektronika IR Elektotechnika, ISSN 1392 -
1215, Vol. 19, No. 8, 2013.
[6] T.R.Simmons, D. Runyan, K.K.Y. LIU, R.M.Paroli, A.H. Delgado & J.D. Irwin,
Effect Of Welding Parameters on seam strength on thermoplastic polyolefin (TPO)
roofing membranes, Proceeding of the North American Conference on Roofing
Technology.
[7] Ruukki Resistance welding manual
[8] Daniel S.Codd KVA Incorporated, Seam Welding and Cooling – Control Heat –
Treatment of Martensitic Stainless Steel, SAE International Technical Paper Series
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[9] Ali. Moarrefzadeh, Study of Heat Affected Zone (HAZ) in Resistance Welding
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267 Avishi Gupta, Dr. K. M. Moeed