Department of Mechanical Engineering

Electronics
EEE 2105

Instructor
Abu Syed Md. Jannatul Islam
Assistant Professor
Dept. of EEE, KUET, BD

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 Resistance Welding
Resistance welding is a liquid state welding process in
which the metal to metal joint created in liquid or
molten state. It is a thermo-electric process in which
heat is generated at the interface surfaces of welding
plates due to electric resistance and a controlled low
pressure is applied to these plates to create a weld
joint. It is named as resistance welding because it uses
electric resistance to produce heat.

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 Resistance Welding Principle
➢ When a current passes through electric resistance, it produces
heat. The amount of heat produced is depends on resistance of
material, surface conditions, current supplied, time duration of
current supplied etc. This heat generation takes place due to
conversion of electric energy into thermal energy. The heat
generation formula is H = I2RT.
➢ This heat is used to melt the interface metal to form a strong
weld joint by fusion. This process produces weld without
application of any filler material, flux and shielding gases.
Where
H = Heat generated in joule
I = Electric current in ampere
R = Electric resistance in Ohm
T = Time of current flow in second
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 Resistance Welding Principle
Principle of Resistance Welding
➢ Apply force and current
through electrodes contacted
metal parts to be welded
➢ Resistance heat is generated at
the interface of metal parts and
makes a nugget, resulting in
melt joint.
➢ Though a large current flows,
there is no danger of an
electric shock because only low
voltage is impressed.

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 Basic Circuit of Resistance Welding

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 Types of Resistance Welding
There are four main type of resistance welding.
These are:
➢Spot welding
➢Seam welding
➢Projection welding
➢Flash butt welding

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 Spot welding

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 Spot welding
➢ It is simplest type of resistance welding in which the work pieces are
held together under pressure of anvil face.
➢ The copper electrodes are brought in contact with work piece and
current start to flow through it. The work piece material applies some
resistance in flow of current which cause local heat generation.
➢ At the interface surfaces the resistance is high due to air gap. The
current start to flow though it which melt down the interface surface.
The amount of current supply and time should be sufficient for proper
melting of interface surfaces.
➢ Now the current stopped to flow but the pressure applied by electrode
maintained for a fraction of second, while the weld rapidly cooled.
➢ After it, the electrodes remove and brought to contact at other spot. It
will create a circular nugget. The nugget size depends on size of
electrode. It is generally about diameter 4-7 mm.

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 Seam welding

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 Seam welding
➢ Seam welding is also called continuous spot welding in which a roller
type electrode is used to flow current through work pieces.
➢ First the rollers are brought in contact with work piece. A high ampere
current is passed through these rollers. This will melt the interface
surfaces and form a weld joint.
➢ Now the rollers start rolling at work plates. This will create a
continuous weld joint.
➢ The timing of the weld and movement of electrode is controlled to
assure that the weld overlap and work piece does not get too hot.
➢ The welding speed is about 60 in/min in seam welding. It is used to
create air tight joints.

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 Projection welding

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 Projection welding
➢ Projection welding is same as spot welding except a dimple is
produced on work pieces at the location where weld is desired.
➢ Now the work pieces held between electrode and a large amount of
current pass through it.
➢ A small amount of pressure is applied through electrode on welding
plates.
➢ The current pass through dimple which melt down it and the pressure
causes the dimple flatten and form a weld.

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 Flash butt welding

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 Flash butt welding
➢ It is another type of resistance welding which is used to weld tubes and rods in
steel industries.
➢ In this process, two work pieces which are to be welded will be clamped in the
electrode holders and a high pulsed current in the range of 100000 ampere is
supplied to the work piece material.
➢ In this two electrode holders are used in which one is fixed and other is
movable. Initially the current is supplied and movable clamp is forced against
the fixed clamp due to contact of these two work pieces at high current, flash
will be produced.
➢ When the interface surface comes into plastic form, the current is stopped and
axial pressure is increased to make joint.
➢ In this process weld is formed due to plastic deformation.

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 Application
➢ Resistance welding is widely used in automotive
industries.
➢ Projection welding is widely used in production of
nut and bolt.
➢ Seam welding is used to produce leak prove joint
required in small tanks , boilers etc.
➢ Flash welding is used to welding pipes and tubes.

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 Advantages and Disadvantages
Advantages:
➢ It can weld thin (0.1 mm) as well as thick (20mm) metals.
➢ High welding speed.
➢ Easily automated.
➢ Both similar and dissimilar metals can be weld.
➢ The process is simple and fully automated so does not
required high skilled labor.
➢ High production rate.
➢ It is environment friendly process.
➢ It does not require any filler metal, flux and shielding gases.

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 Advantages and Disadvantages
Disadvantages:
➢ High equipment cost.
➢ The thickness of work piece is limited due to current
requirement.
➢ It is less efficient for high conductive materials.
➢ High electric power required.
➢ Weld joints have low tensile and fatigue strength.

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Oscilloscope
 What is Oscilloscope

Oscilloscope is a laboratory instrument commonly

used to display and analyze the waveform of
electronic signals. In effect, the device draws a graph
of the instantaneous signal voltage as a function of
time.

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 Types of Oscilloscope
ANALOG CRO :
It is the simplest and earliest type of oscilloscope
comprises of a vertical amplifier, a cathode ray tube,
time base, a power supply and a horizontal amplifier.
These are commonly known as analog CRO.
DIGITAL CRO :
It is a complex electronic device composed of various
software and electronic hardware modules that work
together to capture, process, display and store data
that represents the signals of interest of operator

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 Invention of Oscilloscope
• In 1897, Karl Ferdinand Braun invented
the oscilloscope, which was an adaptation
that he made to the cathode ray tube.

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 Parts of the Oscilloscope

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Application of Oscilloscope
• Show electrical waves
• Communications
• The medical field

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Cathode Ray Oscilloscope
The Cathode Ray Oscilloscope is an instrument
which we use in laboratory to display measure and
analyze various waveforms of various electrical
circuit and electronic circuits. Actually cathode ray
oscilloscope is very fast X-Y plotters that can display
an input signal versus time or other signal. Cathode
ray oscilloscope uses luminous spot which is
produced by striking the beam of electrons and this
luminous spot moves in response variation in the
input quantity. The general forms of cathode ray
oscilloscope operate on voltages.
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Cathode Ray Oscilloscope
So the input quantity that we have talked above is
voltage. Nowadays, with the help of transducers it is
possible to convert various physical quantities like
current, pressure, acceleration etc. to voltage thus it
enable us to have a visual representations of these
various quantities on cathode ray oscilloscope.
Now let us look at the constructional details of the
cathode ray oscilloscope

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Cathode Ray Oscilloscope
The main part of cathode ray oscilloscope is cathode ray
tube which is also known as the heart of cathode ray
oscilloscope.
Let us discuss the construction of cathode ray tube in
order to understand the construction of cathode ray
oscilloscope. Basically the cathode ray tube consists of
five main parts and these main parts are written below:
❖ Electron gun
❖ Deflection plate system
❖ Fluorescent screen.
❖ Glass envelope.
❖ Base.
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Cathode Ray Oscilloscope

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Cathode Ray Oscilloscope
Electron Gun:
It is the source of accelerated, energized and focused
beam of electrons. It consists of six parts namely
heater, a cathode, a grid, a pre-accelerating anode, a
focusing anode and an accelerating anode.

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Cathode Ray Oscilloscope
➢ The control grid with its negative bias, controls the
number of electrons or indirectly we can say the
intensity of emitted electrons from cathode.
➢ After passing through the control grid these electrons
are accelerated with the help of pre-accelerating and
accelerating anodes. The pre-accelerating and
accelerating anodes are connected to a common
positive potential of 1500 volts.
➢ Now after this the function of the focusing anode is to
focus the beam of the electrons so produced. The
focusing anode is connected to adjustable voltage 500
volts.
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Cathode Ray Oscilloscope

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Cathode Ray Oscilloscope

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Cathode Ray Oscilloscope
Advantages of CRO
Resolution and Aspect Ratio: it operates at any resolution,
geometry and aspect ratio without the need for rescaling the
image.
Highest Resolutions: it runs at the highest pixel resolutions
generally available.
High Contrast level: it produces highest contrast level suitable
for use even in dimly light or dark environment.
Fast Response: CRT gives fast response to the signal so it is
best for a rapidly moving and changing wave.

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Cathode Ray Oscilloscope
Disadvantages of CRO
Very Sensitive : sensitive device and requires complete
isolation from noise prone resources.
Physical: they are very large ,heavy and bulky. they
consume a lot of electricity and produce a lot of heat.
Brightness: relatively bright but not as bright as lcd’s. its
not suitable for very brightly lit environment.
Control terminals : there are lots of control terminals
over the control panel that leads to a greater complexity
of the device making it difficult to use.

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Cathode Ray Oscilloscope
USE & APPLICATION OF CRO
TO SEE THE WAVEFORMS- we can see the waveform of
input signal with the help of CRO.
FREQUENCY MEASUREMENT -Using a CRO we can
determine the frequency of the unknown waveforms.
Mathematically: (y axis value X CH*)=T(time period)
So, Frequency=1\T.
VOLTAGE MEASUREMENT- Y AXIS of waveform give the
amplitude value of input signal in volt.
IT IS USE IN DESINE OF NEW CIRCUIT- CRO is strictly
advise to see the exact output of new develop circuit. And to
check the defective components in new circuit.
IT IS BASICALLY USE IN SCIENTFIC AND ENGINEERING
APPLICATIONS.
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