UNITROL ELECTRONICS 702 LANDWEHR ROAD NORTHBROOK, IL 60062

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1 RECOMMENDED PRACTICES FOR SINGLE-PULSE SPOT WELDS IN LOW CARBON STEEL Thinnest Outside Piece Major and Shape ing Spacing MFG GAUGE (mm).00 (0.).0 (0.).00 (0.7).0 (0.9).0 (.).00 (.).07 (.9).090 (.9).0 (.7).0 (.0) / / / / 7/ ,00,00,00,00 (0 HZ) 0 9 0,000,00,000 9,0 0,00,00,00,700,00 7,00 7/ 7/ 9/ / / / / -/ - - -/ ,0,,0,,00,00,900 Starting values shown are based on industry experience. Adjust these values as needed reach required weld quality. Type of steel: SAE Table is for a : maximum ratio of thickest thinnest piece, and a maximum stackup thickness of T material: RWMA CLASS 70 LANDWEHR ROAD NORTHBROOK, IL 00 Phone: Fax:

2 RECOMMENDED PRACTICES FOR PROJECTION WELDS IN LOW CARBON STEEL Thickness DATA COMMON TO ALL CLASSES OF PROJECTION WELDS Projection Size Spacing WELDING SCHEDULE A FOR A SINGLE PROJECTION ing MFG. GAUGE (mm) (0.).07 (0.9).0 (0.).0 (.07).0 (.).00 (.).07 (.9).090 (.9).0 (.7).0 (.0). (.) Thickness Height WELDING SCHEDULE B FOR PROJECTIONS Total Do not mult. Per INCH INCH (0 HZ) ing Min. 0 9 Total Do not mult. Per ,0,,00,0,00,00,00,000,00 0,00,00,0,00,00,00 ing ,00,00,00,,,0,00,00 WELDING SCHEDULE C FOR OR MORE PROJECTIONS Min. MFG GAUGE 9 0 (mm).0 (0.).07 (0.9).0 (0.).0 (.07).0 (.).00 (.).07 (.9).090 (.9).0 (.7).0 (.0). (.) (0 HZ) ,000,00,0,0,00,000,00 7,0,0 9,70 0,00,00,0 7,00,7,0,00,0,0,0 (0 HZ) Starting values shown are based on industry experience. Adjust these values as needed reach required weld quality. Material should be free from scale oxides, paint, grease and heavy oil Material: RWMA CLASS or LANDWEHR ROAD NORTHBROOK, IL ,000,900,00,00,00,00,00,00 7,0,00 9,0 9, ,,70,,900,00, Phone: Fax:

3 LOW CARBON STEEL SPOT WELDING DATA FOR SINGLE-PULSE WELDS IN HEAVY PLATES Plate Thickness Major and Shape Forge ing (mm) / (.) / (.7) (.) (9.) /,000,000,000,00 (0 HZ),000 0,000,00, ,00 9,00,00 9,0,90,00,70 (.70) -,00,00 00,00,00 Starting values shown are based on experience of member companies. Adjust this value as needed reach required weld quality Type of steel: SAE 0-00 Material should be free from scale oxides, paint, grease and heavy oil weld spacing: / / plate =, plate = material: RWMA CLASS LOW CARBON STEEL SPOT WELDING DATA FOR MULTIPLE-PULSE WELDS IN HEAVY PLATES Combination Of Thicknesses To Be ed Major and Shape For Each Pulse Cool Cycles (0 Hz) Cycles ing NUMBER OF PULSES First Additional s Distance To Adjacent T (mm) / (.) / (.) / (.) / (.7) / (.7) / (.7) (.) (.) / (7.9) T (mm) / (.) / (.7) (.) / (.7) (.) / (7.9) (.) / (7.9) / (7.9) D. MIN ,00,00,00,90,90,90,0,0,00 inch inches 0 inches inches,000,000,000 9,00 9,00 9,00,00,00 INCH -/ -/ -/ INCH 9/ 9/ 9/ / / Starting values shown are based on experience of member companies. Adjust these values as needed reach required weld quality. Type of steel: SAE weld spacing: / / plate =, / plate = material: RWMA CLASS 70 LANDWEHR ROAD NORTHBROOK, IL 00 Phone: Fax: ,000,000,000 0,000 0,000 0,000,000,000,000

4 RECOMMENDED PRACTICES FOR SINGLE-PULSE SPOT WELDS IN STAINLESS STEEL Piece Major and Shape ing Spacing Ultimate Tensile of Metal FOR MATERIAL WITH TENSILE STRENGTH Below (0 ) Above (0 ) & up MFG. GAUGE (mm) (0 HZ) LBS LBS LBS.00 (0.).00 (0.) / / / / 0 0 / / / / (0.).0 (.00) / / /,00 / / (0.).0 (0.9) / / 00 0,00,000,0,00 / (0.).0 (0.) / / 0 00,00,000,00,0 / / / (0.0).00 (0.7).0 (0.).0 (0.9).0 (.07).0 (.).0 (.7).00 (.).07 (.70).07 (.9).090 (.9).0 (.7) / / / / / / / / ,000,0,0,00,700,900,00,00 0 0,000,000 7,000 7,00,700 9,00 0,00,000,00,000,700 7,700,00,00,00,00 7,000 7,00,00 9,000 0,000,000,700,000.0 (.0) /,00,000,00.00,000,000 7,00 Starting values shown are based on industry experience. Adjust this value as needed reach required weld quality.. spacing shown is for the welding of two pieces. Increase spacing by 0% when welding three pieces. Smaller minimum spacing requires higher current. material: RWMA CLASS or CLASS Type of steel: AISI 0, 0, 0, 0, 0,, 7,, 9 Table is for a : maximum ratio of thickest thinnest piece, and a maximum stackup thickness of T 7/ 7/ 7/ 9/ / / / 7/ 9/ / / -/ ,000,0,0,700,90,00,700,0, ,70,0,700,00,00,00,0, ,00,00,700,0,900,0,000,00,00 70 LANDWEHR ROAD NORTHBROOK, IL 00 Phone: Fax:

5 RECOMMENDED PRACTICES FOR MULTIPLE-PULSE SPOT WELDS IN STAINLESS STEEL Piece (mm) / (.9) / (.7) / (.) (.) Major and Shape MANUFACTURING DATA FOR PROJECTION WELDS IN STAINLESS STEEL Piece,000,000,00 7,000 HEAT COOL NUMBER OF PULSES 7 ing ing FOR MATERIAL WITH TENSILE STRENGTH Below (0 ),700,00 Above (0 ) 7,00,00 9,000,000 Hold Spacing / - -/ Ultimate Tensile of Metal 90 0 LBS 7,00 9,70 0,00,00 Starting values shown are based on industry experience. Adjust this value as needed reach required weld quality.. spacing shown is for the welding of two pieces. Increase spacing by 0% when welding three pieces. Smaller minimum spacing requires higher current. material: RWMA CLASS Type of steel: AISI 0, 0, 0, 0, 0,, 7,, 9 Table is for a : maximum ratio of thickest thinnest piece, and a maximum stackup thickness of T 0 & up LBS 0,000,00,000 7,000 MFG GAUGE 9 (mm).0 (0.).0 (0.).00 (0.7).0 (.07).00 (.).07 (.9).090 (.9).0 (.7).0 (.0) ,0,900,900,00,00 (0 HZ) ,00,70,70,000 7,00 0,000 0,000,000,000 (0 HZ) 0 0 Starting values shown are based on industry experience. Adjust this value as needed reach required weld quality. material: RWMA CLASS or CLASS Type of steel: AISI 0, 0, 0, 0, 0,, 7,, 9 Projection geometry should be similar chart on PROJECTION WELDS IN LOW CARBON STEEL 70 LANDWEHR ROAD NORTHBROOK, IL 00 Phone: Fax:

6 RECOMMENDED PRACTICES FOR SPOT WELDS IN HIGH STRENGTH LOW ALLOY (HSLA) STEEL Piece Major and Shape ing Spacing MFG GAUGE (mm).00 (0.).0 (0.).00 (0.7).0 (0.9).0 (.).00 (.).07 (.9).090 (.9).0 (.7).0 (.0) / / / / 7/ ,0,0,70,900,00 (0 HZ) 0 7 7,000,00,700,000 9,700,000,00,0,900,00 7/ 7/ 9/ / / / / -/ - - -/ Starting values shown are based on experience of member companies. Adjust this value as needed reach required weld quality. When using radiussed electrodes, increase welding current approximately 0% over values shown. Table is for a : maximum ratio of thickest thinnest piece, and a maximum stackup thickness of T material: RWMA CLASS Material should be pickled or otherwise cleaned obtain a surface contact resistance not exceeding 0 microhms ,70,70,0,00,90,0,90, LANDWEHR ROAD NORTHBROOK, IL 00 Phone: Fax:

7 RECOMMENDED PRACTICES FOR SPOT WELDING ALUMINUM ALLOYS ON SINGLE PHASE MACHINES Piece Major and Shape ing Ultimate Tensile of Metal 9. & up (mm) R. MAX. (0 HZ) INCH LBS LBS LBS.0 (0.0).0 (0.) -Flat -Flat 0,000, (0.).0 (0.).00 (.0).00 (.7).0 (.0).07 (.0).00 (.0).090 (.9).00 (.). (.) -Flat -Flat -Flat -Flat -Flat ,00, ,00 0,700,000,900,000,00,000,000 7, ,0,7,70, ,,,00, ,0,00,700,00,0 Piece Starting values shown are based on industry experience. Adjust this value as needed reach required weld quality. This table is for commercial welding. See table below for single phase welding meet more rigid requirements. Table is for alloys: -T-T-T, -T-T, and 707-T. Somewhat lower values can be used for alloys such as 0, 0, 009, 00,, and material: RWMA CLASS Major and Shape RECOMMENDED PRACTICES FOR SPOT WELDING ALUMINUM ALLOYS ON SINGLE PHASE MACHINES WITH SLOPE Heat Tensile WELD FORGE UPSLOPE WELD HEAT DOWN SLOPE INITIAL WELD FINAL (mm).0 (0.0).0 (0.).00 (.0).0 (.0) R. MAX ,0,0,0,00,70 (0 HZ) (0 HZ) 0 (0 HZ),00,00 0,00,0 7,700 9,00,00,00 0,00 0,00, (.9),700,00 7 7,700,00,0,09. Starting values shown are based on industry experience. Adjust this value as needed reach required weld quality. Table is for alloys: -T-T-T, -T-T, and 707-T. Somewhat lower values can be used for alloys such as 0, 0, 009, 00,, and material: RWMA CLASS This table is for more rigid welding requirements. See table above for single phase welding meet less rigid commercial requirements. 70 LANDWEHR ROAD NORTHBROOK, IL 00 Phone: Fax: ,....

8 RECOMMENDED PRACTICES FOR SINGLE-PULSE SPOT WELDS IN GALVANIZED STEEL The following GALVANIZED STEEL schedule uses a PREHEAT COOL TIME WELD sequence and can only be used with welding controls having this ability. A. The PREHEAT liquefies the galvanized coating but does not have enough current start the weld. B. The COOL TIME allows time for a majority of the liquefied galvanized coating be squeezed away from the weld zone and from under the electrodes. C. The WELD TIME does the actual welding with minimal interference of the galvanized coating. Thinnest Outside Piece Major and Shape ing Preheat Pulse) Preheat Cool Spacing MFG GAUGE (mm).0 (0.0).0 (0.7).0 (0.).00 (.0).0 (.).0 (.).07 (.9).09 (.).0 (.7). (.0) ,00,00,900,00 (0 HZ) 0 0 7,00,70,000,00,000,000,00 9,00 9,00 9,700 (0 HZ),0,00,00,700 7,000 7,00 9,00 9,700 9,00 9,00 (0 HZ) 7/ 7/ 9/ / / / / -/ - - -/ ,00,0,70,90,000,0,00 Starting values shown are based on industry experience. Adjust these values as needed reach required weld quality. COOL TIME is the delay time between the last cycle of PREHEAT and the first cycle of WELD Type of steel: Galvanized G90 Table is for a : maximum ratio of thickest thinnest piece, and a maximum stackup thickness of T material: RWMA CLASS 70 LANDWEHR ROAD NORTHBROOK, IL 00 Phone: Fax: