WELDING NUMERICAL

NUMERICAL
Following data has been observed for a constant
voltage arc welding machine
If the arc length changes from 3mm to 4mm
Voltage changes from 24 to 32 V
Current changes from 200A to 150A

Find out the open circuit voltage(OCV) and

short circuit current (SSC) of the power source.

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 NUMERICAL

V 4mm
OCV
3mm

32V
24 V

I SSC
150 A 200 A
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 NUMERICAL
USING THE EQUATION OF STRAIGHT LINE

Y= mX + c (1)

Y= Voltage
m= slope = V/ I = 8/(-50) = -0.16
X= current
c = Open Circuit Voltage (Y-intercept)
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 NUMERICAL
Therefore eq 1 becomes

V = c 0.16 I (2)

Value of c could be found by putting the values of

V & I for any arc length (given)
Therefore c = 56V

Similarly Value of SSC could be calculated by

putting the value of V=0 , c= 56 in the eq (2)
SSC = 350A
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 Resistance Welding (RW)
The heat generated in resistance welding
H = I2R t (1)

Hw HL
Heat lost into the
Heat used to
work metal,
form weld
electrodes, and
Nugget
surrounding air
say 60%
say 40%
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 Resistance Welding (RW)
Therefore the heat generated in resistance welding which
is used to form the weld nugget can be expressed as
H = k I2R t (2)
H = the total heat generated in the work, J
I = electric current, A
t = time for which the electric current is passing through the
joint
R = the resistance of the joint, 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. )
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 NUMERICAL- Q
A resistance spot-welding operation is performed on
two pieces of 1.5-mm-thick sheet steel using
12,000A for a 0.20 s duration. The electrodes are 7
mm in diameter at the contacting surfaces.
Resistance is assumed to be 0.0001 , and the
resulting weld nugget is a sphere of 6 mm in
diameter. The unit melting energy for the metal
U=12.0 J/ mm3. What portion of the heat
generated was used to form the weld nugget, and
what portion was dissipated into the work metal,
electrodes, and surrounding air?
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 NUMERICAL- Ans

The heat generated in the operation (H) eq 1

Volume of weld nugget = vol of sphere dia 6mm

Heat required to weld the nugget (HW ) = vol X U

Heat Lost (HL ) = (H ) - (HW )