Spot Welding Parameters Basic Calculation

𝐸 = 0.241𝑃𝑡w .........................(1) where E : Energy (J)

*Calculation for AC spot welding P : Power (W)
tw : Weld time (sec)

= 0.241𝐼2𝑅𝑡w .........................(2) where I : Welding Current (A)

R : Panel Contact Resistance (Ω)

= JvSL .........................(3) where Jv : Melting energy (J/mm3)

S : Surface contact (mm2)
L : Total plate thickness combination (mm)

𝑑2
= Jv[π 4
]L ........................(4) where d : Required nugget diameter (mm)
Since 𝑑 = 4 𝑡min for general spot point
= 5 𝑡min for important spot point
Where 𝑡min : Min thickness of panel combinations

(4 𝑡 min)2
So, 0.241𝐼2𝑅𝑡 = Jv[π ]L .......(5) Combination eqn (2) & eqn (4)
4
= Jv[π4𝑡min]]L .............(6)

Final equation;
2 Jv[π4𝑡 min]]L
𝐼= ..............(7) *Used for minimum nugget diameter requirement (general)
0.241𝑅𝑡 w

2 𝑑2
Jv[π ]L
4
= ....................(8) *Used for specific required nugget diameter
0.241𝑅𝑡 w
Note :
Steel type Melting Energy Contact Resistance
Low Carbon Steel 9.7 J/mm3 100 μΩ
3
Aluminum 2.9 J/mm 75 μΩ
 Replace 𝐸 = 0.241𝑃𝑡w to 𝐸 = 0.37𝑃𝑡w for MFDC / DC spot welding calculation

𝐹w = 250𝑡min .............................(9) where 𝐹w = Welding Force (kg) - target

*Go to Quadratic approximation for best data fitting (refer reference) – No 11

𝑡w = 10𝑡min .............................(10) where 𝑡w = Weld time (cycle) – 50 hz

𝑡hold = 3 ~ 5 𝑐𝑦𝑐𝑙𝑒𝑠.................... where 𝑡hold = Hold time (cycle) – 50 hz

*𝑡squeeze - Pneumatic Gun : Min 17 cycle – Min time require for applied force to stable at 80%
- Servo Gun (robot) : 0 cycles – Using integrated robot function (robot will send
signal once applied force is stable to welding
controller)
Servo Gun : 4 cycle – Min time require for applied force to stable
 References

1. Spot Welding Process Sequence

2. Relationship between welding force & resistance

𝐹w = 𝑃w𝐴 .............(1) where Fw : Weld Force

Pw : Weld Pressure
A : Contact Area
𝜌𝐿
R= 𝐴 ........(2) where R : Resistance, Ω

𝜌𝐿
So, A= 𝑅 ........(3) ρ : Resistivity , Ω/mm

L : Total plate thickness combination (mm)

A : Contact Area, mm2
Combine eq (1) & (3)............

𝑃w𝜌𝐿
𝐹w = 𝑅 ........................(4) 𝐹w α 1 𝑅 .... Force ↑ Resistance ↓
 3. Relationship between welding force & welding current

𝑃p = 𝑉𝐼 = 𝐼2𝑅 .................................................(5) where Pp : Weld Power

Combine eq (4) & (5)............

𝑃w𝜌𝐿𝐼2
𝐹w = 𝑃p ............................(6) 𝐹w α 𝐼2 .... Force ↑ Current ↑

*Lobe curve sample from Lobe Curve Generator – Welding Force vs Weld Current
 4. Welding Condition Graph (Base on formulas)

Using derived formulas as above, the new plot (yellow & blue colours) are published against original
welding chart to confirm the accuracy of the formulas. Also, the Lobe Curve estimator was
programmed to view weldability region as following sample;
 5. Lobe Curve Generator (from equations) – Weld Time vs Weld Current

*Improved Lobe Curve Generator

6. AC vs DC Spot Welding Comparison
 7. Lobe Curve Sample (Experimental Data)
Graph 3

Weld Current versus Weld Time Graph

14000
weld_current_total vs. weld_time_total

13000 fit 1
weld_current_total_NF vs. weld_time_total_NF
Spatter Region fit 2
12000
weld_current_total_SP vs. weld_time_total_SP
fit 3
11000
Weld Current (A)

10000

9000 Applicable Region

8000 Small Nugget Region

No Fusion Region

7000 Required Nugget Diameter : 5.5mm

6000
6 8 10 12 14 16 18 20
Weld Time (cycle)

Graph Part Combination Nugget Diameter (Standard) Welding Pressure

SPCC (1.2) x SPCD-SD (1.4)

3 5.5mm 250kgf
x SPRC 40 (2.0)

8. Welding Stepper Program Sample

UNDERBODY ROBOT UB053 / 054 (WELDING PARAMETER SETTING)

IS
WAS
STEPPER 0 STEPPER 1 STEPPER 2 STEPPER 3 STEPPER 4 STEPPER 5 STEPPER 6 STEPPER 7 STEPPER 8 STEPPER 9

CURRENT
11.3 9.5 9.7 9.9 10.1 10.3 10.5 10.7 10.9 11.1 11.3
(kA)

WTM 7 3 3 3 4 4 5 5 5 6 6

WELD COUNT 1~420 1~420 421~840 841~1260 1261~1680 1681~2100 2101~2520 2521~2940 2941~3360 3361~3780 3781~4200

WELD TIME
13 13
(cycle)
PRESSURE
250 250
(kgf)

Welding Current Setting versus Welding Current Actual

11300
11100
10900
10700
10500
Welding Current (A)

10300
10100
9900
9700
9500

Welding Current Setting

Welding Current (Actual)

0 420 840 1260 1680 2100 2520 2940 3360 3780 4200
Weld Count (no)
9. Stepper versus Typical Welding Comparison (Sample)

10. Weld Force Quadratic Approximation

11. Electrode Force Effect on Lobe Curve Range (Sample from experiments)
Electrode Pressure Effect on Applicable Region (Between Standard Nugget & Spatter Region)

Press_160_current_std vs. Press_160_weld_time_std

11500
fit 1
Press_160_current_spatter vs. Press_160_weld_time_spatter
11000 fit 2
Press_200_current_std vs. Press_200_weld_time_std
fit 3
10500 Press_200_current_spatter vs. Press_200_weld_time_spatter
fit 4
Spatter Region

10000

9500
Weld Current (A)

9000

160 kgf
8500

200 kgf
8000

7500

7000

Small Nugget Region

6500

6 8 10 12 14 16 18 20 22
Weld Time (cycle)
12. Shear Load versus Weld Nugget diameter

Shear Load Graph (Ordinary Weld)

8000
SPCE Shear vs. Nugget Diameter
fit [<390 MPa]
SPFC490 Shear vs. Nugget Diameter
7000 fit [390MPa<TS<490MPa]
SPFC580 Shear vs. Nugget Diameter
fit [490MPa<TS<580MPa]
SPFC780 Shear vs. Nugget Diameter
6000 fit [580MPa<TS<780MPa]
SPFC980 Shear vs. Nugget Diameter
fit [780MPa<TS<980MPa]
SPFC >980 Shear vs. Nugget Diameter
5000 fit [TS>980]
Shear Load, F [N]

4000

3000

2000

1000

2.5 2.7 2.9 3.1 3.3 3.5 3.7 3.9 4.1

Nugget Diameter, d [mm]

Shear Load Graph [Critical Weld]

11000 <390 MPa

fit [<390MPa]
10000 390MPa < TS<490MPa
fit [390<TS<490]
490MPa<TS<580
9000 fit [490<TS<580]
580<TS<780MPa
8000 fit [580<TS<780
780<TS<980MPa
Shear Load, F [N]

fit [780<TS<980]
7000 TS>980
fit [TS>980]
6000

5000

4000

3000

2000

3.4 3.6 3.8 4 4.2 4.4 4.6 4.8 5

Nugget Diameter, d [mm]
13. Temperature Distribution During Spot Welding

14. Dynamic Resistance Measurement (IJAME)

15. Welding Heat Distribution (SAE)