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2a1 Physics Spot Weld
2a1 Physics Spot Weld
expulsion pulsing
Projection Welds
Spot Weld
Seam Weld
Electrodes or Dies
Projection Weld
Upset Weld
Flash Weld
After Welding
After Welding
Distance
(a)
(b)
Difficulty for maintenance or repair Adds weight and material cost to the product, compared with a butt joint Generally have higher cost than most arc welding equipments Produces unfavorable line power demands Low tensile and fatigue strength The full strength of the sheet cannot prevail across a spot welded joint
Squeeze Time
Electrode Force
Upslope Time
Cool Time
Downslope Time
Preheat Time
Quench Time
Squeeze time
Weld Time
Preweld Interval
Weld Interval
Welding Cycle
Postweld Interval
Temper Time
Hold Time
Contact-Resistance Measurement
Electrode Rec Force Small Current Rec Rsc Rtotal Rec Rv Rv
Contact Area
Rec Electrode Force
Resistivity, mW-cm
HSLA
Low Carbon
Temperature, C
[Reference: Welding in the Automotive Industry, D.W. Dickinson, p.125]
Turn to the person sitting next to you and discuss (1 min.): The total resistance across the spot weld for plain carbon steel usually starts high because of interfacial surface asperities and oxides and surface contaminants. But the total resistance changes as current passes. What would be the value of resistance as time increases (dynamic resistance)? Draw a curve.
Resistance
Number of Cycles
Work
Water Temperature Welding Temperature
Electrode Water
Nugget Growth
(a) (b)
Point 1
Point 2
Point 3
Zhang et al, Expulsion Modeling in RSW of Steel and Al Alloys, AWS Sheet Metal Conf VIII, 1998
This illustration was taken about 4/60th of a second after the welding current starts.
Zhang et al, Expulsion Modeling in RSW of Steel and Al Alloys, AWS Sheet Metal Conf VIII, 1998
Zhang et al, Expulsion Modeling in RSW of Steel and Al Alloys, AWS Sheet Metal Conf VIII, 1998
Zhang et al, Expulsion Modeling in RSW of Steel and Al Alloys, AWS Sheet Metal Conf VIII, 1998
Pulsing
Pulse 1 Pulse 2 Pulse 3
Pulse Time
Cool Time
Without Pulsing
With Pulsing
Turn to the person sitting next to you and discuss (1 min.): We have seen the nugget growth with AC current to grow when the peak in current is reached and shrink slightly as the current goes to zero each half cycle. What might occur when DC current is used?