Welcome to Scribd, the world's digital library. Read, publish, and share books and documents. See more
Download
Standard view
Full view
of .
Look up keyword
Like this
0Activity
0 of .
Results for:
No results containing your search query
P. 1
1.2 Resistance and Special Welding

1.2 Resistance and Special Welding

Ratings: (0)|Views: 4 |Likes:
Published by nikhilbatham

More info:

Published by: nikhilbatham on Aug 21, 2013
Copyright:Attribution Non-commercial

Availability:

Read on Scribd mobile: iPhone, iPad and Android.
download as PDF, TXT or read online from Scribd
See more
See less

08/21/2013

pdf

text

original

 
8/26/20111
Resistance
 
 Welding
By 
 
S
 
K
 
Mondal
Resistance
 
Welding
 
Principle
y
Both heatand pressureareused.
y
Heat is generated by the electrical resistance of the work piecesand the interfacebetween them.
y
Pressure is supplied externally and is variedthroughouttheweld cycle.
y
Due to pressure, a lower temperature needed thanoxy 
fuelorarcwelding.
Contd…
y
They are not officially classified as solid
state weldingbytheAmericanWelding Society.
y
Veryrapid and economical.
y
Extreme ywe suite toautomate manu acturing.
y
Nofillermetal, no flux, noshielding gases.
Contd…
 
y
Overall resistancevery low.
y
Veryhigh
current(upto100,000A)
y
Verylow
 voltage(0.5 to10V) isused.
FIG.
 
The
 
fundamental
 
resistance
 welding
 
circuitFig. The desired temperaturedistribution across theelectrodes and the workpieces in lap resistance welding.
Fig. Typical current andpressure cycle for resistancewelding. The cycle includesforging and post heatingoperations.
Fig. The arrangement of the electrodes and the work in spot welding,showingdesignforreplaceableelectrodetips.
 
8/26/20112
Advantages
1.Veryrapid.2. Fullyautomationpossible.. , ,flux isrequired.4. Skilled operatorsare notrequired.5.Dissimilarmetalscan beeasily joined.6. High reliabilityand Highreproducibility.
Limitations
1. High initialcost.2. Limitationstothetypeof joints (mostly lap
joints).
.4. special surface treatment needed.
Application
y
The resistance welding processes are among themost common technique for high volume joining.
Different
 
types
1.
Resistancespotwelding
2.
Resistanceseamwelding
3.4.
Upsetwelding
5.
Flashwelding
6.
Percussionwelding
Resistance
 
spot
 
welding
y
The process description given so far is called resistancespotwelding (RSW) orsimplyspotwelding.
y
This is essentially done to join two sheet
metal jobs ina lap joint, forming a small nugget at the interface of thetwo plates.
Heat
 
input
 
and
 
Efficiency
 
Calculations
Contd…
 
8/26/20113
ElectricResistanceWelding
 Joule’s lawapplicableQ = I
2
Rt, JoulesCalculate the melting efficiency in the case of arc welding of steel with a potential of 20 V and current of 200 A. The travel speed is 5 mm/s and the cross
sectional area of the joint is 20 mm
2
. Heat required to
Example
1
 
melt steel may be taken as 10 / and the heat transferefficiencyas 0.85.[PTU
2004]
Example
2
Calculate the melting efficiency in the case of arc
 welding of steel with a potential of 20 V anda current of 200 A. The travel speed is 5 mm/s
.mm
2
. Heat required to melt steel may be takenas 10 J/mm
3
and the heat transfer efficiency as0.85.
Example
3
Two steel plates each 1 mm thick are spot welded atacurrentof 5000 A. The currentflowtime is 0.1 s. The electrodes used are 5 mm in.its distribution in the weld zone. The effectiveresistance in theoperation is 200
μΩ
.
Example
4
Two steel sheets of 1.0mm thickness areresistance welded in a lap joint with a current of 10 000 A for 0.1 second. The effective resistance. joint can be considered as a cylinder of 5 mmdiameterand 1.5mm height. The density of steelis 0.00786 g/mm
3
and heat required for meltingsteel is 10 J/mm
3
.How much heat would be generated in the spot welding of two sheets of 1 mm thick steel thatre uired a current of 10000 A for 0.1 seconds?
Example
5
 Aneffective resistance of 100
μΩ
. isassumed.

You're Reading a Free Preview

Download
scribd
/*********** DO NOT ALTER ANYTHING BELOW THIS LINE ! ************/ var s_code=s.t();if(s_code)document.write(s_code)//-->