Beruflich Dokumente
Kultur Dokumente
Projection Welding
Seam Welding
Butt Welding
Flash Welding
High Frequency
Capacitive Discharge
Electro-Brazing
Other Resistance Welding Processess
Lesson Objectives Learning Activities
When you finish this lesson you will 1. View Slides;
understand: 2. Read Notes,
• Projection Welding & Applications 3. Listen to lecture
• Seam Welding & Applications 4. Do on-line
• Butt Welding & Applications workbook
• Flash Welding & Applications
• High Frequency Welding & Applications
• Capacitive Discharge Welding &
Applications
• Electro Brazing & Applications
Welding Current
Cool Time
Downslope
Upslope
Preheat
Quench
Time
Temper
Hold
Squeeze
Time
Time
Time
Time
Time
Time
Weld
Preweld Time
Interval Weld Interval Postweld Interval
Welding Cycle
Pulsing
Pulse 1 Pulse 2 Pulse 3
intersections.
Link to Projection Welding video
Process Fundamentals
Process Fundamentals
• Two parts, one projected, are
placed upon one another
between two electrodes.
• They make contact at the
projected point.
• High current starts to flow B.
through projection. A.
• Force is applied to cause the
heated projection to collapse, Formation of a projection weld.
(a)
(b)
(i) (j)
[Reference: Welding Handbook, Volume 2, p.562, AWS]
Projection Design
Projection Design
Projection should be
Spherical radius
– sufficiently rigid to support
the electrode force.
– have adequate mass to heat a
spot. Wall thickness
D
Projection
should blend
– collapse without metal should be at least into stock
70% of sheet surface without
expulsion. thickness shouldering
Continuous Seam
Weld
Workpiece
Throat
Electrodes Overlapping
Weld
Nuggets
Travel
Weld Nuggets
Flash
Broad, Flat
Electrode
to a transformer.
• A voltage is applied as
one part approaches B. Apply flashing voltage
other.
Flash Welding Process
• Upon contact, resistive
heating occurs.
• High amperage causes C. Flash
Transformer
Transformer
Ring weld
Flash Welding Applications
• Wheel rims in the automotive industry
• Motor and generator frames in the electrical
industry.
• Landing gear, control assemblies and hollow
propeller blades in the aircraft industry.
• Typical metals used are stainless steel,
aluminum, copper, and nickel alloys.
Introduction to Upset Welding
To Welding Transformer
Upsetting
Force
Movable Part
Stationary Part
Abrasion-Resistant
Cemented Tungsten
Carbide Tip
Resistance Butt
Welded to Carbon
Steel Sole
Attachment
HF
HF
HF
Pipe Butt Bar Butt
[Reference: Welding Handbook, Volume 2, p.653, AWS]
Advantages of High-Frequency
Welding
• Produce welds with very narrow heat-affected zones
• High efficiency
Limitations of High-Frequency
Welding
• Special care must be taken to avoid radiation interference in
the plant’s vicinity
• Uneconomical for products required in small quantities
Current Passed,
Melts Solder,
Ingles, G et al “Braided Buss Bar with Selectively Clad
Bond Made
Solder Pad Attachments” US Patent 6,042,932 Mar 28, 2000