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Spot Welding
Lesson Objectives
When you finish this lesson you will
understand:
Basics of Resistance Welding Processes
Heat Generation & Control
Spot Welding Process and Applications
Learning Activities
1. View Slides;
2. Read Notes,
3. Listen to lecture
4. View Demo
5. Do on-line
workbook
Definition of Resistance
Welding
Resistance welding is a fusion welding process in
which coalescence of metals is produced at the
faying surfaces by the heat generated at the joint by
the resistance of the work to the flow of electricity.
Force is applied before, during, and after the
application of current to prevent arcing at the work
piece.
Melting occurs at the faying surfaces during
welding.
Electrodes
or Welding
Wheels
Spot Weld
Electrodes
or Dies
Seam Weld
Projection
Welds
Projection Weld
Electrodes or Dies
Upset Weld
After Welding
Flash Weld
After Welding
(a)
(b)
High Speed
Economical
Dimensional Accuracy
Resistance Welding
Resistance welding depends on three
factors:
Time of current flow (T).
Resistance of the conductor (R)
Amperage (I).
Heat = I2 RTK
Where
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses
Is a function of:
Transformer Tap Setting
Material Prop., & Pressure
Control Setting
Conduction, Convection,
Radiation
Spot Weld
N=np/ns
Vs= Vp/N
Is = Ip N
Heat = I2 RTK
Where
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses
Is a function of:
Transformer Tap Setting
Material Prop., & Pressure
Control Setting
Conduction, Convection,
Radiation
Contact-Resistance Measurement
Electrode
Rec
Force
Small Current
Rec
Rsc
Rtotal
Rec
Rv
Rv
Contact
Area
Rec
Electrode
Force
Surface
Condition
(a) Pickled Conditions
Steel
(b) Rusted Conditions
Oils/Dirt
Oxide
Steel
Resistivity
Steel
Rusty
Polished
Pickled
Oxide
Oils/Dirt
Electrode Force
Steel
Low Pressure
(a)
Medium Pressure
(b)
High Pressure
(c)
Volume-Resistance Measurement
Electrode
Force
Small Current
Rec
Rsc
Rtotal
Rec
Rv
Rv
Contact
Area
Rv
Electrode
Force
Resistivity, -cm
HSLA
Low Carbon
Temperature, C
[Reference: Welding in the Automotive Industry, D.W. Dickinson, p.125]
Heat = I2 RTK
Where
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses
Is a function of:
Transformer Tap Setting
Material Prop., & Pressure
Control Setting
Conduction, Convection,
Radiation
Current
Electrode
Pressure
Weld Current
Temper Current
Upslope
Downslope
Temper
Squeeze Time
Weld Time
Off Time
Hold Time
Heat = I2 RTK
Where
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses
Is a function of:
Transformer Tap Setting
Material Prop., & Pressure
Control Setting
Conduction, Convection,
Radiation
Heat Dissipation
Water-Cooled Copper Alloy Electrode
Base Metal
Weld Nugget
Base Metal
Heat = I RTK
Where
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses
Is a function of:
Transformer Tap Setting
Pressure
Control Setting
Conduction, Convection,
Radiation
Distance
Weld
Nugget
Resistance
Bottom Electrode
Workpiece
At the end of
welding time
After 20%
welding time
Electrode
Workpiece
Temperature
distribution
at
various
location
during
welding.
Electrode
Temperature Distribution
Temperature
Nugget Solidification