WHAT IS WELDING?

Welding is the process of joining metas

FILLER MATERIAL

MELTING JOINING
HEAT
OF METAL OF METAL

1. E. CURRENT NO FILLER MATERIAL

2 GAS
3 CHEMICAL
REACTION
 HOW MANY TYPES
WELDING ARE THERE?
1. ARC WELDING

2. RESISTANCE WELDING

3. GAS WELDING

4. LASER BEAM WELDING

5. THERMIT WELDING ETC.

TYPES OF RESISTANCE
WELDING
1. SPOT WELDING

2. PROJECTION WELDING

3. FLASH WELDING

4. SEAM WELDING

5. BUTT WELDING
 WHAT IS RESISTANCE WELDING?

In this process, an electrical

current flows through resistive
circuit to generate enough heat
between two pieces of sheet
metal so that the metal reaches
molten stage.The resistance to
the flow of current is provided
by the work piece.The
maximum heat is generated at
the point of maximum
resistance.
 Resistance welding
H=I2xRxT.
H = Heat
I2 = Current in amperes,
R = Resistance of the work in 0hms,
T = Time the current flow in cycles
( 50 CYCLES IN ONE SECOND)
Resistance welding
Resistance & Effect of Pressure
R1&R5 Resistance between tip and sheet
R2 & R4 sheet individual resistance
R3 Surface contact resistance
R1
In welding it is
R2 desirable to have
R3 •R1,R2,R4,R5 low
•R3 high
R4
R5
TYPES OF WELDING POWER SUPPLIES

1.A.C Welding power supply

2.Capacitor-Discharge power supply

3.Transistor power supply

4.Frequency Inverter power supply

5.A.C Inverter welding power supply

 FOUR MAJOR ELEMENTS OF
WELDING
* WELD CURRENT

* WELD TIME

* PRESSURE

* ELECTRODE SHAPE(CURRENT DENSITY)

 CURRENT
SQEEZE
UP SLOPE

WELD

DN SLOPE
SPOT WELDING

TIME
HOLD

OFF
WELD TIME CONTROL FOR
TIMER CONTROLLER
WELD TIME CONTROL FOR SPOT WELDING

1 . SQUEEZE TIME TIME REQUIRED FOR THE ELECTRODE

TO CLOSE ON METAL AND APPLY PROPER PRESSURE. IT
VARIES WITH THE GAP BETWEEN THE ELECTRODES .

2. UPSLOPE TIME TIME TAKEN FOR THE CURRENT TO

REACH FROM ZERO THE PEAK VALUE.
3. WELD TIME TIME REQUIRED FOR PEAK
CURRENT TO FLOW AND HEAT THE METAL
4. DOWN SLOPE TIME TIME TAKEN FOR THE
CURRENT TO CUT OFF I.e, FROM PEAK TO ZERO
WELD TIME CONTROL FOR SPOT WELDING

5. HOLD TIME TIME TAKEN BY THE ELECTRODES TO

HOLD THE SHEETS TOGETHER AFTER THE CURRENT
FLOW STOPS. PRESSURE STILL APPLIED TO ALLOW
THE MOLTEN METAL TO SOLIDIFY.
6. OFF TIME IT IS THE TIME BETWEEN THE END OF ONE
SPOT SEQUENCE TO START OF NEXT SPOT SEQUENCE
 WELDING CURRENT FEATURES AND MEASUREMENT
WHY CURRENT CAN NOT MEASURE WITH AMETER
In spot welding ,large current flows for very short time (0.02 sec -0.5 sec ), AMETER cannot
respond so quickly.

HOW TO MEASURE THE CURRENT

Flux
In spot welding current is measured with Toroidal coil
When high current flows it generates magnetic
field and magnetic flux interlink with the coil
generate Electromotive force in proportion to rate of change Current
of current to time V = K di/dt K is constant i
Coil
Electromoti
ve force
i
V
Coil output V is in proportion to the coil
area and nos. of turns This type of sensor can measure any large current in differential value To
get absolute value it is interlink with electronic circuit.
How to check current?

Toroidal coil

Weld checker
Resistance welding
Relation between Current and time

A :- WILL HAVE
LESS WORK DISTORTION
Current
A LESS OXIDATION

B GOOD WELDABILITY

C
Time A: Strong current and short time
C: Small Current and long time
B:Medium current and medium time
Effect of Pressure
*Brings sheet into intimate contact thus
effect contact resistance
*Ensures completion of electric circuit
*Ensures heat dissipation in weld zone and
prevents surface fusion.
*If low: Surface burning and pitting of
electrode
*If High: More current is required.
*Measure the pressure between electrodes
with calibrated pressure gauge only.
How to check pressure?

Pressure gauge

Electrode
Welding parameters board
Resistance welding
Relation between Current and Pressure

No Nugget
Large
Splash
Nugget Dia B - will have
Pressure

(Strength) d
el Good Weld
W Less Spatters
od
Small o Explosion Optimum Nugget Dia
G

Current
A:High Current and High Pressure
B:Medium current and medium Pressure
C: Small Current and High Pressure
 PROPERTIES AND FUNCTION OF ELECTRODES
REQUIREMENT OF ELECTRODES
1. ELECTRODES CENTERED AND FIXED SECURILY TO ELECRODES HOLDER
2. FREE MOVEMENT ALLOWING FOR CONSITTENT PRESSURE REPEATABILITY
3. QUICK RESPONSE OF THE ELECTRODE ARM ALLOWS FOR PRESSURE TO BE MAINTAINED DURING
WELDING
4. ELECRODES MUST HAVE LOW NATURAL RESITANCE, HIGH HEAT CONDUCTIVITY AND
MAINTAINED HARDNESS EVEN AT HIGH TEMPERATURES
5. HIGH CONDUCTIVITY ELECTRODES ARE USED FOR LOW CONDUCTIVE MATERIALS AND LOW
CONDUCTIVE ELECTRODES BEING USED FOR HIGH CONDUCTIVE MATERIAL
FUNCTIONS OF ELECTRODES
1. SUPPLY SUFFICIENT WELDING CURRENT TO THE REQUIRED AREA
2. HEATING DURING WELDING AND QUICK COOLING AFTER WELDING
3. DEFINE THE WELDING ZONE AND MAINTAIN CORRECT PRESSURE
SHAPE OF ELECTRODES
1. AS TIP OF THE ELECRODE DETERMINE THE WELDING AREA ON THE WORK PIECE IT IS NECESSARY
TO MAINTAIN THE CONTANT SHAPE FREE FROM WEAR
2. MANY TYPES OF SHAPES ARE USED IN ELECTRODES

F - TYPES CF - TYPES
P - TYPES R - TYPES CR - TYPES

THE MOST COMMONLY USED ELECTRODES SHAPES ARE P AND CR TYPES.

 PROPERTIES AND APPLICATIONS OF ELECTRODES

ELECTRODES MATERIAL CONDUCTANCE APPLICATIONS

( IACS % )
Copper Cu 97 Few applications but good for F types of electrodes

Chrome copper CuCr 75-80 Generally used for Ferrous materials and stainless steel

NBC alloys Ni Be Cu 55 Good for ferrous materials , SUS and Nickel

Beryllium copper Cu Be 50 Good for SUS and ferrous material

Tungsten silver AgW 40-45 High hardness and less abrasion

Tungsten copper CuW 30-35 High hardness and less abrasion

Tungsten W 29 Good for Copper and Brass

Molybdenum Mo 30 Same as tungsten electrodes