Resistance Welding. Resistance Welding (RW)

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1 Resistance Welding (RW) Resistance Welding 1 Resistance Welding is a welding process, in which work pieces are welded due to a combination of a pressure applied to them and a localized heat generated by a high electric current flowing through the contact area of the weld. The weld is made by a combination of HEAT, PRESSURE, and TIME. Resistance of the material to be welded to current flow causes a localized heating in the part. 2 1

2 Resistance Welding (RW) Resistance Welding (RW) This HEAT produced is sufficient for local melting of the work piece at the contact point and formation of small weld pool( nugget ). The molten metal is then solidifies under a PRESSURE and joins the pieces. The pressure exerted holds the parts together before, during, and after the welding current time cycle. TIMEoftheprocessandvaluesofthepressureand flowing current, required for formation of reliable joint, are determined by dimensions of the electrodes and the work piece metal type. 3 The heat generated in resistance welding H w Heat used to form weld Nugget say 60% H = I 2 R t (1) H L Heat lost into the work metal, electrodes, and surrounding air say 40% 4 2

3 Resistance Welding (RW) Therefore the heat generated in resistance welding which isusedtoformtheweldnugget canbeexpressedas H = k I 2 R t (2) H=thetotalheatgenerated inthework,j I=electriccurrent,A t = time for which the electric current is passing through the joint R=theresistanceofthejoint,ohms k= a constant to account for the heat losses from the welded joint. (if k=0.6, that means 40% of the heat is lost into the work metal, electrodes, and surrounding air.) 5 4 Major Points Of Resistance There are 4 major points of resistance in the work area. They are as follows: (R1) (R2) (R3) (R4) Resistance of the electrodes. The contact resistance between the electrode and the workpiece. The contact resistance between the two workpiece plates. The workpiece resistance. 6 3

4 Current Voltage R2 R4 R1 FORCE R3 WELD SPOT OR NUGGET AC low volt (typically 1 volt ) electric current (up to 100,000 A) is supplied through copper electrodes connected to the secondary coil of a welding transformer. FORCE WELDING TEMPERATURE 7 8 4

5 APPLICATIONS Resistance Welding(RW) is used for joining vehicle body parts, fuel tanks, domestic radiators, pipesofgasoilandwaterpipelines, wireends, turbine blades etc. SHEET METAL PRODUCTS Metals Welded The following metals may be welded by Resistance Welding: Low carbon steels - the widest application of Resistance Welding Aluminum alloys Medium carbon steels, high carbon steels and Alloy steels

6 ADVANTAGES High welding rates Low fumes Cost effectiveness Easy automation No filler materials are required Low distortions Good repeatability and reliability High equipment cost DISADVANTAGES Low strength of discontinuous welds Thickness of welded sheets is limited -up to (6 mm) Limited to lap joints for most RW processes

7 Types of Resistance Welding (RW) The most popular methods of Resistance Welding are: 1. Spot Welding (RSW) 2. Seam Welding (RSEW) 3. Resistance Projection Welding (RPW) Spot Welding (RSW) Spot Welding is a Resistance Welding (RW) process, in which two or more overlapped metal sheets are joined by spot welds. The method uses pointed copper electrodes providing passage of electric current. The electrodes also transmit pressure required for formation of strong weld. Diameteroftheweldspotisintherange-(3-12 mm). Spot welding is widely used in automotive industry for joining vehicle body parts. Typicalcarbodyhas~10,000spotwelds 14 7

8 1. Spot Welding (RSW) 1. Spot Welding (RSW) -STEPS Thesequenceisasfollows: 1. parts inserted between open electrodes, 2. electrodes close and force is applied, 3. weld time current is switched on, 4. current is turned off but force is maintained or increased (a reduced current is sometimes applied neartheendofthisstepforstressreliefintheweld region), and 5. electrodes are opened, and the welded assembly is removed

9 1. Spot Welding (RSW) -STEPS 1. Force, Current vs Time Welding Current PostweldHeating Current (1) parts inserted between electrodes, (2) electrodes close, force applied, (3) current on, (4) current off, (5) electrodes opened. 17 (1) parts inserted between electrodes, (2) electrodes close, force applied, (3) current on, (4) current off, (5) electrodes opened. 18 9

10 1. Spot Welding (RSW) - POSTWELD It has been observed that steels containing more than 0.15% carbon may result into brittle weld joint during resistance welding. Therefore postweld heating is sometimes applied to eliminate possible brittleness. 2. Resistance Projection Welding (RPW) A resistance welding process in which coalescence occurs at one or more small contact points on parts Contact points determined by design of parts to be joined May consist of projections, embossments, or localized intersections of parts

11 2. Resistance Projection Welding (RPW) In a mass-production operation, conventional spot welding is plagued by two significant limitations. 1. Because the small electrodes provide both the high currents and the required pressure, the electrodes generally require frequent attention and re-work (repair) to maintain their geometry. 2. In addition, the process is designed to produce only one spot weld at a time. 2. Resistance Projection Welding (RPW) When increased strength is required, multiple weldsare often needed, and this means multiple operations. Projection welding(rpw) provides a means of overcoming these limitations. Figure illustrates the principle of projection welding

12 2. Resistance Projection Welding (RPW) A dimple is embossed into one of the workpieces at the location where a weld is desired. The two workpieces are then placed between largearea electrodes in a press machine, and pressure and current are applied as in spot welding. Since the current must flow through the points of contact (i.e., the dimples), the heating is concentrated where the weld is desired. As the metal heats and becomes plastic, the pressure causes the dimple to flatten and form a weld. 23 Resistance projection welding (RPW): (1) start of operation, contact between parts is at projections; (2) when current is applied, weld nuggets similar to spot welding are formed at the projections

13 3. Seam Welding (RSEW) Seam Welding is a Resistance Welding (RW) process of continuous joining of overlapping sheets by passing them between two rotating electrode wheels. Heat generated by the electric current flowing through the contact area and pressure provided by the wheels are sufficient to produce a leak-tight weld. Resistance seam welds (RSEW) can be made by two distinctly different processes. 3. Seam Welding (RSEW) 1. In the First Process, sheet metal segments are joined to produce gas- or liquid-tight vessels (Leak proof), such as gas tanks, mufflers, and simple heat exchangers. The weld is made between over-lapping sheets of metal, and the seam is simply a series of overlapping spot welds, like those shown in Figure

14 3. Seam Welding (RSEW) 3. Seam Welding (RSEW)

15 3. Seam Welding (RSEW) The basic equipment is the same as for spot welding, except that the electrodes now assume the form of rotating disks. As the metal passes between the electrodes, timed pulses of current form the overlapping welds. The timing of the welds and the movement of the work are controlled to ensure that the welds overlapandtheworkpiecesdonotgettoohot Seam Welding (RSEW) In a variation of the process, a continuous current is passed through the rotating electrodes to produce a continuous seam. This form of seam welding is best suited for thin materials,butmetalsupto6mmcanbejoined. Atypical weldingspeedisabout2m/minforthin sheet

16 3. Seam Welding (RSEW) Seam Welding is high speed and clean process, which is used when continuous tight weldisrequired. Can produce air-tight joints Applications: Gasoline tanks Automobile mufflers Various other sheet metal containers 31 Resistance Butt Welding 2. The second type of resistance seam welding, known as resistance butt welding,is used to produce seam welded tubes and pipes. Figshowsthedetailsoftheequipmentused. Current up to 40,000A at about 5V is introduced across the joint by the split electrode roller and force applied by pressure rolls. A transformer with slip rings on the primary side isusedasapowersource

17 Resistance Butt Welding Large quantities of tubes are made by electric resistance butt-seam welding process. Tubes are produced from strips by feeding the strips through set of forming rollers. Theseformingrollersformtheinitialshapeofthe tube and then it is passed under the seam welding rolls. Resistance Butt Welding Both work motion and current are kept continuous during the process. Frequency up to 350 Hz are used in practice with speeds of 36m/min

18 Production Of Seam Welded Tubes/Pipes Slip Rings Split Electrode Roller Forming of initial shape of the tube

19 Production Of Seam Welded Tubes/Pipes Functions of ELECTRODES Split Electrode Roller Slip Rings Power Supply RESISTANCE WELDING ELECTRODES perform four functions: 1. Conduct the welding current to the work. 2. Transmit a force to the workpieces. 3. Dissipate part of the heat from the weld zone. 4. Maintain relative alignment and position of the workpieces in projection welding

20 Desirable Properties of ELECTRODES 1. Electrodes should have high electrical and thermal conductivities and must develop low electric contact resistance in order to prevent deterioration of the work-piece and electrodes. 2. Since the electrodes are subjected to forces that are often of considerable magnitude, they must have good strength to resist to deformation and wear at high temperature. Desirable Properties of ELECTRODES Proper electrode shape is important because the currentmustbeconfined toa fixed area to achieve needed current density

21 Electrode Material Electrode Cooling Commonly used electrode materials are purecopperand copper base alloys. Pure tungsten or tungsten-silver or pure molybdenum may also be used as electrode material. To reduce wear, tear and deformation of electrodes, cooling through water circulation is required. WATER FORCE 41 21

22 ELECTRODE Shapes Electrodes are composed of three parts: the electrode cap or tip, the body of the electrode and the cooling system. Mostoftheelectrodesarecylindricalwiththetip machined to a truncated cone with an angle of 30 degrees, though a variety of tip shapes (flat, dome and eccentric) is used to obtain access with complex joints. Commonly Used ELECTRODE Shapes Pointed

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