Chapter a4 RESISTANCE WELDING 24.0 General Whenever a heavy electric current is passed through a material, the material will offer resistance to the flow of current. This results in local heating of the material. This principle is used to generate the required heat at the joint for welding. The quantity of heat generated in the material due to the current flow is given by Joules law + QaPFrRt Q = 024% x Px Rxt i, Time of flow of current in sec Resistance in the circuit in Ohms Heit Current in the circuit in amperes. generated Constant of proportionally in calories Heat generated is very rapid as very high currents of 300 — 10° amps with a voltage upto 25 volts is used, A transformer is used for the purpose. AC source is used. The parts to be joined are heated to plastic state and high pressure is applied. This results in a joint, after cooling. Current consumed depends on the area of contact and time. Pressure applied is approximately around 25 ~ 55 N/mm. No filler metal is required for the purpose. Copper electrode is used to carry the current to the joint. Resistance welding can be used for all metals except tin, lead and zine as they pose several problems. Advantages of Resistance Welding Fast rate of welding possible No filler rod required Semi skilled workers can be employed Both similar and dissimilar metals can be welded Very high reliability and reproducibility obtained in the welds. Semi automatic equipments can be used. Disadvantages of Resistance Welding # Initial cost of equipment is high Needs good control and maintenance of equipments © Higher thickness of metal cannot be welded.360 Manutacturing Process Process is simple and the operation is very rapid. Used for mass production Application of Resistance Welding © Used for joining sheets, bars, rods and tubes. # Used for welding aircraft and automobile parts * Used for general engineering fabrication purposes like grills, containers, tanks, etc Types of resistance welding : |. Butt welding 2. Spot welding 3. Seam welding 4, Projection welding 5. Percussion welding 24.1 Butt Welding ‘Two metal pieces of the same cross section are held together by clamps and pressed. A current is now applied through the secondary coil of the transformer. Heat is generated at the contact surface and a joint results, The weld joint will be bulging and round. It has to be machined. Fig. 24.1 shows this Clamps Bulge Work ee 3 is a 00000000 Completed —— weld joint [ WOOeDNT Lo ‘Supply o—! Fig. 24.1 : Butt Welding 24.2 Spot Welding It is the simplest form of resistance welding. Mainly used for welding sheet metal, both ferrous and non-ferrous metals of 8 mm thick and less. Consists of two electrodes (water cooled) one fixed and another moveable. The sheets are cleaned first and are placed between the electrodes. Bottom electrode is fixed and the top electrode is moveable. By operating a foot lever the moveable electrode is brought in contact with the sheet and a pressure of 22 — 55 N/mm’ is applied. A low voltage of 30 —40V and high current of 120 — 300 amps is passed between the electrodes, This results in intense heat and the sheet gets welded within 10 — 15 sec. Soon after the current isResistance Welding 361 switched off with pressure on. After the weld cools, pressure is released. Materials having higher thermal conductivity can be easily welded. Fig. 24.2 shows the details. Movable electrode 4 Sheet Fixed electrode Fig. 24.2 : Spot Welding 24.2.1 Spot Welding Cycle During one welding cycle there will be 4 different timings involved. Fig. 24.3 shows this Squeeze time — it is the time (0-1) between the initial application of pressure on the work through the electrode and the initial application of current for making the weld. Full electrode pressure is obtained during the period. Upper electrode comes in contact with it and full pressure is realised. Slowly the pressure is increased and maintained as welding current is applied. Weld time — period 1 ~ 2 weld current is applied through the electrodes for a known time. Hold time — The pressure is maintained after welding at full pressure for some time then cooled to pt.3. Off time for the next cycle. the time interval from the end of the hold time (o the starting of squeeze time Squeeze _, Weld Hold _y ogy g if | S| a 6 Start pone é " Current | \ 0 i —— Time | Fig.24.3 : Spot Welding Cycle362 Manufacturing Process 24.3 Seam Welding Here two copper wheels act as electrodes through which current is passed and pressure is applied, Cu electrode Fig. 24.4 : Seam Welding Work pieces are kept between the electrodes and current is passed through the electrodes and pressure is applied. A weld is formed. Continuous weld is formed as the work is moved between the electrodes. Heat is generated due to the flow of current and the work offers resistance to this. Either current or pressure can be varied to control the heat generated. This changes the contact resistance, A series of overlapping welds are formed and the spacing can be controlled by controlling the movement of the work. Used for making continuous welds between two overlapping sheets of metal for producing water tight joint. Fig. 24.4. shows the det \ | Movable arm ——o Copper plate Supply aa) Fig. 24.5 : Projection WeldingResistance Welding 363 24.4 Projection Welding Similar to spot welding. Copper platens are held in the arms. The work pieces are held in position in the arms. One piece has projections and the other is flat. Current is passed and pressure is applied. The projections flatten and the two pieces get welded. Large number of welds can be done at various points by having projections. Any metal or alloy can be welded 24.5 Percussion Welding Percussion welding (PEW) is a resistance welding process in which the heat is obtained from an are produced by a rapid discharge of electrical energy and force is percussively applied during or immediately afier the electrical discharge. The are produced between the work melts a shallow layer on the surface of contact. One of the work pieces is impacted against the other, extinguishing the arc, expelling molten metal and completing the weld. The electrical resistivity of the parts being welded does not noticeably effect the amount of heat generated at the joint. The Arc Supplies the Heat For Welding, The work holding clamp, of the welding head does not have to be a good conductor as in resistance welding because current is small and brief. The heat input is intense, but extremely brief and localised. This enables the Percussion welding of Small component to another small or large one, Even dissimilar metals that differ considerably in electrical resistivity and melting temperature, can be PEW with ease. Arc initiation, Arc time and welding force are controlled and synchronised automatically. Fig. 24.6 shows this Sliding clamp Fixed clamp — Trigger Lea = Power Supply Fig. 24.6 : Percussion Welding364 Manufacturing Process Principle of Percussion Welding A high voltage potential from a large — capacitor is applied to the parts to be butt welded which are held apart against a heavy spring pressure, by a trigger mechanism. When the trigger is released, the sliding clamp moves the work under high force rapidly. When the distance between the parts has diminished to about 1/32 to 1/16”, the air gap breaks down causing the capacitor to discharge across the high frequency spark gap Power expended — 200 to 300 KVA Time for weld < 0.001 seconds. Power Supply : 1. Low — voltage capacitors; 50 ~ 150 V (high capacitance) 1000 — 3000 V (low capacitance) 2, High voltage capacitor 3. Resistance welding transformer; supplies 60 cycles AC al low voltage In all the above, the electrical energy discharge time is very small Work Piece and Design : © One of the two components to be welded must be designed so that, it can be clamped securely in the welding head and can be impacted against a stationery component without slippage. © Capacitor discharge PEW can be used to butt weld wires of similar dia or greatly different dia The wire dia as small as about 0.005m. (0.127mm) can be welded. © Heat treated, cold worked or prefinished metals are virtually unaffected by the heat of PEW, because HAZ is very shallow (0.0381 to 0.127mm). © Heat input is so concentrated at the weld interface and so short duration, that the metal more than few thousandth of an inch from the weld interface is unaffected by the heat. Applications : 1) Itis used for making electrical connections and el 2) Used for welding fine wire leads to filaments in lamps and terminals of electrical and electronic components. 3)_Itis used for producing butt or T-joints between wires, tubes, etc 4) Flat work p are-starting rib or projec 5) Almost any like and unlike metal/alloy can be joined by PEW. The best example of unlike metal welding is Copper and Molybdenum, Advantages of PEW : ‘© The are time is very short (less than 0.0018) © The HAZ is very shallow © Wire dia is low as 0,127 mm can be welded surfaces with aid of an s of any shape can be percussion welded to mating f 1 on one of the members. * Any like or unlike metal/alloy can be easily welded «Is ideal for welding of wires in communication systems, instrumentation, eteResistance Welding 365 Limitations : © Only small dia wires or tubes can be welded. | © Only Butt or T-joints of work pieces are possible. 24.6 Practical problems associated with Lead, resistance welding in and Zinc alloys in ‘The properties of most importance which influence weldability are Conductivity Expansion characteristics Nature and condition of surface film High temperature strength Structure of the fusion and/or heated affected zone. ‘The principle of resistance welding is based on : Development of heat due to resistance to the flow of current ie Q = I Q— heat developed R — resistance Q @ R for constant I and time. Material Resistivity Lead (Pb) 19.3x 10° Qm Tin (Sn) 10.1 x 10° Qm Zine (Zn) 5.41 x 10*Qm Pb, Sn and Zn being high conductivity materials require more current to give an equivalent heat output due to ¢ Low resistance «Increased conduction of heat away from the weld zone. ‘This demands welding for short times with except need for more complex and expensive equipment. ly high current. Therefore there is a Factors governing the type of mechanical system used in welding machines :- © Co-efficient of thermal expansion © Shrinkage contraction on solidification Materials of high thermal expansion and conductivity requires a high electrode force immediately following the current pulse to avoid shrinkage cavities and cracks.366 Manufacturing Process 24.7 Friction Welding Rotating at high speed Pressure Fig. 24.7 : Friction Welding Heat produced due to friction is utilized and by applying pressure a joint is formed. The heat is enough to fuse the work pieces. One of the work pieces is held stationery and the other work piece pressed against it and kept rotating at high speed, a very high pressure is applied and the rotation is stopped. A perfect joint results, No preparation of the surface required, The surfaces to be welded must be flat. Process is well suited to non ferrous alloys. Pipes, tubes, bars of carbon steel, stainless steel, Al, Ti alloy, steels can be welded with ease. Dissimilar metal can be joined. Initial pressure, heating time and final upsetting pressure can be varied to suit the requirement QUESTIONS . Explain the principle of resistance welding 2. How is resistance welding classified ? 3. Describe the following processes with a neat sketch a) Butt welding b) Spot welding ¢) Seam welding d) Projection welding _e) Percussion welding . What problems are associated with resistance welding of tin, lead and antimony metals? Explain friction welding process. . Explain the principle of resistance welding How is resistance welding classified ? wea awa Describe the following processes with a neat sketch a) Butt welding b) Spot welding c) Seam welding 4) Projection welding —_e) Percussion welding 9. What problems are associated with resistance welding of tin, lead and antimony metals? 10. Explain friction welding process.Resistance Welding 367 Objective Type Questions 24.1 Heat generated in a conductor is used to heat the workpiece locally. True / False 24.2. The principle of heat generation is given by law and can be calculated using the formula 24.3. The order of current is amps with a voltage volts in electric resistance welding. 24.4 Resistance welding consume large amounts of Filler rod. True / False 24.5 Any combination of metals can be welded by resistance welding, True / False 24.6 Higher thickness of metal can be easily resistance welded True / False 24.7 Resistance welding cannot be used for welding aircraft and automobile parts. 24.8. Gas cylinders are resistance welded by _ method. 24.9 Friction welding does not utilize any external source of heat. ‘True / False 24.10 Surfaces of the workpiece needs to be rough for friction welding. ‘True / False 24.11 Lead, Tin and Zine alloys can be easily resistance welded. ‘True / False 24.12. High conductivity materials can be easily resistance welded. True / False 24.13, HAZ in percussion welding is very low. True / False 24.14 Wire diameter as low as 0.127mm can be easily welded by welding 24.15 For butt welding of thin wires welding is used. 24.16 Projection welding is used for sheets. Yes / No Answers 24.1, True 242 Souls FRt 24,3 300 50 24.4 False 24.5 True 246 False 24.7 False 24.8 Seam Welding 24.9 True 24.10 True 24.11 False 24.12 False 24.13 True 24.14 Percussion 24.15 Percussion 24.16 Yes