AWS C1.1M/C1.1:2000 An American National Standard Recommended Practices for Resistance Welding7 AWS C1.1M/C1.1:2000 flash weld, electrode force, weld An American National Standard ccurtent, weld strength, projection ‘weld, Iap joint, upset weld Approved by American National Standards Institute January 31, 2000 Recommended Practice for Resistance Welding Supersedes AWS C1.1-66 Prepared by AWS Committee on Resistance Welding Under the Direction of AWS Technical Activities Committee Approved by AWS Board of Directors Abstract This Recommended Practice is a collection of data and procedures that are intended to assist the user in setting up ‘Fatsiance welding equipment to produce resistance welded production pats, While the recommendations inclados ac, from am final procedures for every production part or every welding machine, they serve as starting points from which a ser can establish acceptable welding machine stings for specific production welding aplication: In some cases, recommended machine data is not availabe. In these instances, some desertion edhe process is siven to assist the reader in determining ifthe process might be suitable for application American Welding Society 550 NW. Leleune Road, Miami, Florida 33126Statement on Use of AWS American National Standards Meandards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Neiing Society ae voluntary consensus standards that have been developed in accordance withthe rules ofthe Avene ational Standards Insitute, When AWS standards are either incorporated in, or made part of deeemente en cn ipeluded in federal or stat laws and regulations, or the regulations of other governmental bodies, thelr pronieene carry Ae El legal authority ofthe statute In such eases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulation. In alt Sr nese standards carry the full egal authority ofthe contractor other document that invokes the AWS srexd ede, Where this contractual relationship exist, changes in or deviations from requirements of an AWS standond tran ho by ‘agreement between the contracting parties. International Standarc! Book Number; 0-87171-601-0 American Welding Society, 550 N.W, LeJeune Road, Miami, FL 33126 © 2000 by American Welding Society. All rights reserved Printed in the United States of America AWS American National Standards are developed through a consensus standards development process that brings area ts presenting varied viewpoints and interests to achieve consensus. 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AWS disclaims liability fr the infringement of any patent resulting from the use or reliance on this standard. nally, AWS doesnot monitor, police, or enforce compliance with his standard, nor does it have the power to do s0 ica interpretations of any ofthe technical requirements ofthis standard may be obtained by sending request, in writ (ce, i the Managing Director Technical Services, American Welding Society, $50 N.W. Leleune Road, Miami, FL 33126 (Gee Annex A). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS sin ahs ‘may ee eadered, However, such opinions represent only the personal opinions of the particular individuals giving them: The, individuals donot speak on behalf of AWS, nor do these oral opinions constitute oficial or unofficial opinions we, interpre- tations of AWS. Inadltion, orl opinions are informal and should not be used asa substitute for an official interpretation tig Committe, A copy of these Rules can be obtained from the American Welding Society, 550 NW. Lelie Road, Miami, FL 33126, Photocopy Rights Auihorization fo photocopy items for intemal, personal, or educational classroom use ony, or the internal, personal o dusatonal classroom ase only of specific clients is granted by the American Welding Society (AWS) provided atthe Sere eis pid to the Copyright Clearance Cener, 222 Rosewood Drive, Danvers, MA 01923, Tel: 978-750-8400, online: http://w ww.copyright.comPersonnel AWS C1 Committee on Resistance Welding P.G.Harris, Chair Centerline Welding, Limited W.H, Brafford, Ist Vice Chair CMW, Incorporated Bd. Bastian, 2nd Vice Chair Bentmar Associates TR Potter, Secretary American Welding Society J.C. Bohr General Motors Corporation RK. Cohen WeldComputer Corporation S.A.D’Angelo Mercury Aireraft, Incorporated. “*D.E, Desiefan High Current Technologies, Incorporated PDem Grumman Aircraft Systems “RJ. Gasser Consultant JM. Gerken Consultant “P-Howe Bethlehem Steel Corporation RW. Jud DaimlerChrysler Corporation ‘M. Kimchi Edison Welding Institute J.W.Lee AlliedSignal Aerospace *D.L. Olson Colorado School of Mines JLPOsborne Ford Motor Company °M, Prager Welding Research Council WF Qualls Valiant International W.T-Shieh Lockheed Martin Corporation Advisor **Conespondence Font yore tae as a wscxor. we noes Crean nay lan an trees yourForeword {This Foreword is not a part of AWS C1.IMICI.1:2000, Recommended Practices for Resistance Welding, but is in- cluded for information purposes only.) sa Conisined in these Recommended Practices have been compiled by the AWS Committee on Resistance Welding, by reviewing the data inthe previous documents, by canvassing users of the resistance welding processes and Paeetous edition of AWS C1.1-66, Recommended Practices for Resistance Welding: AWS C1. 2.83, Recommended eactces for Spor Welding Aluminum and Aluninum Alloys; and AWS C13-10, Recommended Prociece for Resistance Mding Coated Low Carbon Steels. Practices for new materials have been added and practices for marcoole cre are 1o. currently resistance welded in commercial production have been deleted, The new materials inclada high-strength Tow-alloy steels, both coated and uncoated, AWS C1253 included data for clecromagnetic and electrostatic stored energy machines. Since these types of ma- Shines are rarely used anymore having been replaced by more Nexibe direct energy machines, eee dna nae se been ‘The AWS Committee on Resistance Welding has prepared these Recommended Practices in the hhope that they will wrhich will porate nataty to develop methods and procedures improving upon the practice presented herein, sah ul Permit the rising of quality and performance standards. I this is ahicved. the Commitee el nace been ‘amply repaid forthe time and effort it has devoted to this work, Comments and suggestions forthe improvement of this standard are welcome. They should be sent to the Secretary, Commitee on Resistance Welding, American Welding Society, $50 N.W. Leleune Road, Miami FL bieTable of Contents Page No. Personnel. Foreword.. List of Tables. List of Figures 1. Scope... 2. Referenced Documents 2.1 Safety References, 3. Nonstandard Terms and Definitions 4. Resistance Spot and Seam Welding 4.1 Uncoated Carbon and Low-Alloy Steels. 42 Coated Carbon and Low-Alloy Steels 43° Aluminum Alloys a : $4 Stainless Steels, Nickel, Nickel-Base Alloys, and Cobalt Bose Alloys... 4.5 Copper and Copper Alloys. ee — 4.6 Titanium and Titanium Alloys... =e — dg Welding Data Comments and Discussions Applicable to Varows Mec 4.8 Weld Discrepancies and Causes... 7 4.9 Weld Quality and Mechanical Property Tests 5. Projection Welding, 5.1 Introduction. : 5.2 Embossed Projection Welding. 53. Solid Projection Welding... 4 Multiple Projection Welding : 5 Weld Quality and Mechanical Property Tests Flash Welding. 6.1 Introduc 62 Equipment. 63 Welding Variables 64 Welding Variable Measurements. 65 Classification of Steels for Flash Welding 6.6 Joint Preparation and Cleanin 6:7 Welding Schedules : 68 Weld Discrepancies and Causes, : 69 Weld Quality and Mechanical Property Tests. 7. Upset Welding 7.1 Introduction 72 Equipment. 73° Welding Variables 7.4 Joint Preparation and Cleaning. 7.5 Welding Parameters... : : 76 Weld Quality and Mechanical Property Teste 8. Weld Bonding... 8.1 Introduction 82 Aluminum Alloys... Saree eee tam tesotor we, ware83. Other Metals..... 84 Weld Bonding Quality and Mechanical Property Tost 9. Equipment Monitoring and Maintenance .eresunnou o a 90 10. Safety and Health 10.1 General 102 Selection of Equipment 10.3 Operator Training soon. 10.4 Personal Protective Epipmen. 10.5. Installatio 10.6 Guarding. 10.7 Blectrical.. 108 Static Safety Devices 10.9 Ventilation, 10.10 Maintenance .. 10.11 Fire Hazards, 10.12 Noise... 10.13 Lighting 10.14 Signs... 10.15 Hazardous Materials... ‘Annex A—Guldelines for Preparation of Technical Inquiries for AWS Technical Committees. AWS List of Documents on Resistance Welding. Scrassey Fo marterercios ‘Setinsctor, we. wmoeneTable List of Tables Page No. 1 Spot Welding Parameters for Low-Carbon Steel.. 2 Pulsation Spot Welding Parameters for Low-Carbon Steel 3 Seam Welding Parameters for Low-Carbon Stee! ee 4 Spot Welding Parameters for HSLA Stecl (ASTM A 715, Grades 50 and 60) Minimum Yield Suengths 345 t0 415 MPa (50 t0 60 ksi) ss-mnssncensnnssnsnnnsnsrveneaas 5 Spot Welding Parameters for HSLA Steel (ASTM A 715, Grades 70 and 80) Minimum Yield Strengths 480 to 550 MPa (70 to 80 ksi) — a § Spot Welding Parameters for HSLA Steel (ASTM A 568) Minimum Yield Point 380 MPa (5 ka) ng 7 Spot Weld Parameters for Low-Alloy and Medium-Carbon Steels... nn) 8 Electrode Materials for Resistance Welding... : 10 9 Spot Welding Parameters for Galvanized Low Carbon Steel u 10. Spot Welding Parameters for Galvannealed Low-Carbon Stee! : 12 11 Spot Welding Parameters for Galvanized HSLA Steel Minimum Yield Strengths 345, 415, 480, 550, and 620 MPa (50, 60, 70, 80, and 90 ksi) area 12 Seam Welding Parameters for Galvanized Low-Carbon Steel. 13 Basic Aluminum Alloy Groups... o o = — 14 Resistance Weldability Chart for Commonly Used Combinations of Aluminum Alloys (Based on Equal Thickness) ee —— 16 15 _ Recommended Spot Weld Spacing, Edge Distance, Overlap and Distance betweon Rows of Welds for Aluminum and Is AlloyS.... —— 18 15 $80 Welding Parameters for Aluminum Alloys on Standard Single-Phase A-C Type Equipment. 19 Tg Spot Welding Parameters for Aluminum Alloys on Single-Phase AC Slope Control Type Machines 20 13 $Pot Welding Parameters for Aluminum Alloys on Three-Phase Rectifier Type Equipment nn 5y 19 Spor Welding Parameters for Aluminum Alloys on Three-Phase Frequency Converter Type Equipment (Single Impulse Welds) occ reer sna ned 20 Spot Welding Parameters for Stainless Steels, 21 Pulsation Spot Welding Parameters for Stainless Steels 22 Seam Welding Parameters for Stainless Steels. rnin 23. Spot Welding Parameters for Annealed Nickel-Copper Alloy on Single-Phase Equipment 24 Spot Welding Parameters for Annealed Nickel-Copper Alloy on Three-Phase Frequency Converter Machines — — ee 28 32 Seam Welding Parameters for Annealed Nickel-Copper Alay on Single-Phase Equipment 39 26 Seam Welding Parameters for Annealed Nickel-Copper Alloy on Three-Phase Frequency Converter Machines .. so : = ve 30 33 Spot Welding Parameters for Annealed Nickel-Chromium Alloy 600 on Single Phase Equipmoees 31 35 Spot Welding Parameters for Annealed Nickel-Chromium Alloy X750 on Single-Phase Equipment 32 29 Spot Welding Parameters for Annealed Nickel-Chromium Alloy X750 on Three Phase Frequency Converter Machines... = : : e338 30 Spot Welding Parameters for Annealed Nicke-Caromium Alloy X750 on Tiwee-Phase Diy Disc Rectifier Machines, 7 a 34 3p Seam Welding Parameters for Annealed Nicks|-Chromium Alloy X750 on Single Phase Equipment. 38 32 Seam Welding Parameters for Annealed Nickel-Chromium Alloy X750 on Three-Phase Frequency Converter Machines. — : 33 Roll Spot Welding Parameters for Annealed Nickel-Ciromium Alloy X750 on ‘Three-Phase Dry Dise Rectifier Machines. =Page No. 34 Spot Welding Parameters for Annealed Nickel on Single-Phase Eaupment 35. Spot Welding Parameters for Nickel-Iron-Chromium Alloy X : 36 Seam Welding Parameters for Nickel-Iron-Chromium Alloy X. 37 Spot Welding Parameters for Cobalt-Chromium-Nickel Alloy... 38 Spot Welding Parameters for Various Copper Alloys: 39 Spot Welding Parameters for Titanium Alloy 6%AL-4%V 40. Variation of Current Density and Unit Force Due to Lack of Electrode Tip Maintenance, 41 Spot Welding Parameters for Various Thickness Combinations and Arrangements of ‘Uncoated and Coated-Carbon and Low-Alloy Steels... 42 Projection and Die Geometries for Welding a Range of Heavy-Gauge Steels 43. Process Requirements for Projection Welding a Range of Heavy-Gauge Steels. 44° Punch Design Data for Low-Carbon Stee! Projections... 45. Die Button Design Data for Low-Carbon Steel Projections... 46 Punch and Die Design Data for Forming Projections on Stainless Steels. 47 Projection Welding Parameters for Low-Carbon Steel 48 Projection Welding Parameters for Galvanized Low-Carbon Steel 49 Projection Welding Parameters for Stainless Steels 50 Projection Designs and Process Requirements for Annular Projection Welding Some Representative Light-Gange Steels. = 2 51 Projection Welding Design Data for Stainless Steels 3 52 Projections for Low-Carbon Steel 74 53. Process Requirements for Cross-Wire Welding a Range of Thicknesses of Hot. and Cold Drawn Steel Wires . 54 Data for Fash Welding of Tubing and Flat Sheets. 55 Data for Flash Welding of Solid Round, Hex, Square, and Rectangular Bars. 56 Weld-Bonding Surface Preparation for Aluminum Alloys by Low-Voltage Anodizing 57 Comparison between Resistance Spot Welding and Weld-Bonding of Aluminum Alloys . 58 Typical Spot Welding Parameters for 1.6 mm (0.063 in.) Thick 7075-T6 Aluminum Treated with a Low-Voltage Anodizing Process. se 89 59 Commonly Used Metric Conversions Inch-Millimeter Conversion DBList of Figures ‘Standard RWMA Nose or Tip Geometries of Spot Welding Electrodes Coring in Nickel Alloy 718 (UNS NO718) Resistance Seam Weld, 200X Peel Tes : = Peel Test Specimens. seni —— ‘Measurement of a Weld Button Resulting from the Peel Test Bend Test Specimen. os Spot Weld Chisel Test soon. ‘Tension-Shear Test Specimen... = ‘Twisting Angle yat Fracture in Tension Shear Test, Cross-Tension Test Specimens...nnmninuminnrrnecnn, ‘Fixture for Cross-Tension Test (for Thicknesses up to 4.8 mm (0.19 in) Fixture for Cross-Tension Test (for Thicknesses 4.8 mm [0.19 in.] and Over) U-Test Specimen : : U-Tension Test Jig = Pull Test (90-Degree Peel Test)... . 7 ‘Test Specimen and Typical Equipment for Torsion-Shear Test Drop-Impact Test Specimen... : : Drop-Impact Test Machine . a ‘Test Fixture for Shear-Impact Loading Test ‘Test Fixture for Tension-Impact Loading Test Fatigue Testing Machine Pillow Test for Seam Welds = . ‘Typical Stack-up Configuration for Embossed Projection Welding of Sheet, ‘Typical Configuration for Solid Projection Welding... none sgram Defining How Set-Down is Estimated on Cross. Wire Welds ‘Characteristies of Projection Collapse during Annular Projection Welding with Different Base Projection Widths : = . sn 78 27 Chart of Flash Welding Definitions 79 28 Chart of Flash Welding Definitions . 80 29 Flash Welding of Tubing and Flat Sheets 7 82 30 Flash Welding of Solid Round, Hex, Square, and Rectangular Bars... seen 82 31 Comparison of Tensile-Shear Strengths of Uncured and Cured (Single Spot) Weld-Bonded lointe 0f 7075-16 Aluminum Alloy . . : _ : 90 32 Comparison of Fatigue Test Results of Weld-Bonded and Adhesive-Bonded Toints of 1075.16 ‘Aluminum Alloy : = — 33. Fatigue Test Specimen of Weld-Bonded and Adhesive Bonded Joints, 34 Form for Resistance Welding Data Sheet for Spot and Projection Welding, 35 _ Form for Resistance Welding Data Sheet for Seam Welding... : 36 Form for Resistance Welding Data Sheet for Flash or Upset Welding... ix Foch as ecko, ‘Eusmsoncy, wo weanAWS ©1.1MiC1.1 2000 Recommended Practices for Resistance Weiding 1. Scope At is the intent of this publication 0 present current concepts and practices for resistance welding (and re lated processes) of ferrous and nonferrous metals including coated and dissimilar metals. Where practical, welding schedules are included. In other instances where sched. Ules are too varied or the state-of: the-art is not sufficiently developed, descriptive guidelines are included to enable the user to establish welding procedures to meet its requirements, Its important to recognize that these recommended practices are not presented as the only conditions for welding the materials and thicknesses shown, Rather they are offered as a guide for setting up welding sched. ules for any particular fabrication, and may have to be ‘modified according to the specific part conditions and production requirements {In using the data shown in the tables, itis imperative that reference be made to the appropriate text. Failure to refer to the text may result in misinterpretation of the ata inthe tables. The text has been kept as brief as pos- sible and all extraneous comments have been omitted For more detailed information on the fundamentals of the resistance welding processes and the types of equip- ‘ment utilized for the different processes, consult the cur- rent AWS Welding Handbook ‘This standard makes use of both the International Sys- tem of Units (SI) and U.S. Customary Units. The mea- surements may not be exact equivalents; therefore, each system must be used independently of the other without ‘combining in any way. The standard with the designation C1.1M:2000 uses ST units, The standard designation €1.1:2000 uses U.S. Customary Units, The latter are shown within parenthesis () or in appropriate columns in tables and figures. An inch/millimeter conversion table is found in Table 59. 2. Referenced Documents () AWS C1.AMICI.4:2000, Specification for Resis- ‘tance Welding of Carbon and Low-Alloy Steels (2) AWS A244, Standard Symbols for Welding, Braz- ing and Nondestructive Testing (3) AWS 30, Standard Welding Terms and Definitions (4) AWS D8.6, Standard for ‘Spot Welding Electrodes (3) AWS D8.7, Recommended Practices for Automo- tive Weld Quality—Resistance Spot Welding (6) AWS DB.9, Recommended Practices for Test Methods for Evaluating the Resistance Spot Welding Behavior of Automotive Sheet Steels (7) AWS Welding Handbook, Volume 2, Eighth Edi- tion, Chapter 17, “Spot, Seam, and Projection Welding,” American Welding Society (8) AWS PARW, The Professional's Advisor on Resistance Welding, American Welding Society (9) Welding Aluminum: Theory and Practice, Chapter 13 “Resistance Welding,” The Aluminum Association,? Washington DC, 199) (10) ASTM E 340 and E 407, Annual Book of ASTM Standards, Vol, 3.012 (11) ASM Handbook Volume 8: Mechanical Testing,? Resistance Welding Manual, 4th Edition, Resistance ‘Welder Manufacturers’ Association, 1989¢ Automotive Resistance 4. Available rom AA, 900 19th Steet, NW, Washington, DC 20006, 2. Available from American Society for Testing and Materials, 100 Barr Harbor Drive, W. Conshohocken, PA, 19428, 3. Available from ASM International, Materials Puk, OF 44073-0002, 4. Available from RWMA, 1900 Arch Strect, Philadelphia, PA 19103-1498, 1AWS C1.114C1.1:2000 (22)Society of Manufacturing Engineers, Too! and ‘Manufacturing Engineers Handbook, Volume 4, Fourth Edition, 198735 2.1 Safety References (1) ANSIZA9.1, Safety in Welding, Curing, and Allied Processes, published by AWS 2) Effects on Welding and Health, published by AWS ) Safety and Health Fact Sheers, published by AWS (4) Occupational Safety and Health Administration (OSHA), Code of Federal Regulations, Title 29 Labor, Chapter XVII, Past 1910, “Occupational Safety and Health Standards" (5) ANSI Foonvear? (6) ANSI 287.1, Practice for Occupational and Educ cational Eye and Face Protection (7) ANSI Z88.2, Respiratory Protection (8) ANSI 289.1, Protective Headwear for Industrial Workers (©) ASME B15.1, Safety Standard for Mechanical Fower Transmission ApparatusS (10) ANSI 2535.5, Accident Prevention Tags (11) National Institate for Occupational Safety and Health, MOSH Criteria Document, Recommended Stan. dard for Welding, Brazing, and Thermal Cutting, 1988° (12) General Motors Corporation, PED 960, Personnel Safer) Standards for Assembly Plant Equipment and Tools, ‘May, 197 (13) National Fire Protection Association, National Electrical Code! (14) National Fire Protection Association, Standard SIB, Cuting and Welding Processes 241, Personal Protection—Protective 3. Nonstandard Terms and Definitions Most of the following terms are applicable only to re- sistance welding. Flash welding variables are defined in 6.3 For additional welding terms, see AWS A3.0, Stan. dard Welding Terms and Definitions. 3. Available from SME, One SME Drive, PO Box 930, Dear bom, ML 48121, 6. Available from Superintendent of Documents, U.S. Govern ‘ment Printing Office, Washington, DC 20402, 7 Available from American National Standard Insitute, 11 ‘West 42nd Steet, 13th Floor, New York, NY 10036-8002, & Available from ASME International, Three Park Avenue, New York, NY 10016-5990, 9. Available from NIOSH, 4676 Columbia Parkway, Cincin- nati, OF 45226, 10, Available from National Fie Protection Association, One Batterymarch, Quincy, PA 02269, bake-hardenable steel, Low-carbon steel having the Capability of being strengtiened during a subsequent heat teating operation, usually a paint baking process, dent-resistant steel. A general term for low-carbon steels having higher resistance to plastic deformation than standard cold-rolled, low yield strength, low. carbon steels. It encompasses high-stength low-alloy (HSLA), bake-hardenable and dual-phase stests, Boverning metal thickness. The thickness of the sheet (usually the thinnest outer sheet) on which the required igget size and depth of fusion in a resistance weld are based, ‘high-strength low-alloy (HSLA) steel. A general term for low-carbon steel having higher yield strength than Standard low yield strength low-carbon steels. It can be furnished as either a hot or cold rolled product. high-strength steels (HSS). A general group of steels ‘hth greater tensile and yield strengths than low-stength low-carbon steel penetrator, A nonmetallic oxide inclusion in a flash weld. hase shift control. A control commonly used in resis tance welding machines to adjust he initiating point a, Jowing only a portion or percentage of each alternating ‘current half cycle to pass to the welding transformer. mushrooming, The deformation of an electrode, inti- ated at the contact surface asa result of the varicus aes tions occurring during welding. weld discrepancy. A weld condition that deviates from the applicable standard, specification, or engineering drawing, Weld lobe. The current, time, and Provide acceptable welds. force ranges which 4. Resistance Spot and Seam Welding 41 Uncoated Carbon and Low-Aloy Steels 4.1.1 Introduction 4111 Low-Carbon Steels. Low-carbon steels contain less than 0.20% carbon and less than 0.50% man. ganese, with the remaining alloying elements totaling fess than 196. The maximum hardness attainable in ear, bor and low-alloystelsis dependent almost exclusively (on the carbon content. In addition to this effect on maxi, fmuum hardness, carbon has a relatively strong influence in increasing the depth or ease of hardening, Manganese also combines with sulfur and reduces the tendency to- ward hot-eracking. Hot-cracking results from the low 2strength of the steel at high temperatures. The steel can- ‘ot accommodate the stresses which develop during cooling, and cracks form in the weld metal or in the heat- affected zone (HAZ), Low-carbon steels have typical bulk electrical resis- tivities (1e., the specific electrical resistivity of a given volume of metal) of 10-20 uO-cm (4-8 .0-in.), and have large plastic ranges. Both of these characteristics make low-carbon steel quite weldable using resistance welding processes. However, low-carbon steels wi bon levels greater than 0.13% may be suscepti hardening; therefore, the rapid cooling rates of resistance spot and seam welding are of concer for steels contain- ing these levels of carbon. In this carbon range, precau- tions as described for medium and high-carbon steels ‘may be required. Several new designations of low-carbon steels have been incorporated into the nomenclature of the industry. ‘These include bake-hardenable, dent-resistant and inter- stitial-free (I-F) steels, Dent-resistant materials are de- fined as low-carbon steels that have higher resistance to plastic deformation than do the standard low-carbon steels. I-F steels are low-carbon steels which have less than 0.02% carbon with niobium (columbim) and tita- ‘ninm additions to improve formability. Welding of these ‘materials is similar to most low-carbon steels and similar ‘welding schedules can be used. 4.1.1.2 Medium-Carbon and Alloy Steels. Mc- dium-carbon steels contain 0.20-0.55% carbon with the remaining alloying elements totaling less than 1.0%. ‘Steels are considered to be alloy steels when the maxi- ‘mum of the range given for the content of alloying cle- ‘ments exceeds one or more of the following limits: ‘manganese, 1.65% silicon, 0.60%; copper, 0.60%; or in which a definite range or definite minimum quantity for Any of the following clements is specified or required Within the limits of the recognized field of constructional alloy steels: aluminum, and chromium up to 9%; cobalt, niobium, molybdenum, nickel, titanium, tungsten, vana- «dium, zirconium, or any other alloying element edded to obiain a desired alloying effect. Higher carbon levels represent higher hardenability, ‘and care is required when welding these steels, For this, reason, medium-carbon steels have an increased tendency ‘toward embrittlement than do low-carbon steels. Medium- carbon and alloy steels frequently require preheating prior to, and tempering treatments after, welding. These steels ‘may be heat treated on welding equipment with the neces- sary controls, or heat treated as a separate operation, 4.1.1.3 High-Carbon Steels. High-carbon steels contain more than 0.55% and less than 1,50% carbon. ‘These stecls have high hardenability and are not easily resistance welded without weld cracking. Special proce- dures must be used when resistance welding these steels. ‘AWS @1.1MIC1 12000 4.1.1.4 High-Strength Low-Alloy (HSLA) Steels. High-strength, low-alloy steels obtain their strength and ‘other mechanical properties through the addition of al- loying elements, or through thermal processing, or both. Alloying elements may include niobium, vanadium, nitro- gen, phosphorus, or rare earth additions. Thermal processes which impart strength include controlled cooling, recov- ery annealing, and controlied annealing. Yietd strength levels range from 241 MPa (35 ksi) to over 690 MPa (100 ksi), When welding HSLA steels, welding sched- ules may include preweld heat conditioning, or postweld heat treatment to improve the microstnteture of the weld nugget, HAZ, or bath. 4.1.2 Surface Conditions. Prior to welding, the ‘workpiece surface should be free of contaminants which ‘might adversely affect the weld quality. Surface contami- nants and organic coatings can adversely affect the ‘chemical composition of the weld, Uncoated steel is typically classified as either hot- rolled or cold-rolled. The hot-rolled product is supplied in two conditions, hot-rolled, or hot-rolled, pickled and oiled. Hot-rolled steel sheet develops a tenacious mill scale which has a very high contact resistance, Cold-rlled and hot-rolled, pickled and oiled stee! sheets do not ex- hibit mill scale because the mill scale is removed during the material processing. Low-carbon and HSLA steel shects are typically supplied in both the hot-rolled, pickled and oiled, and cold-rolled conditions. Materials in these con- ditions are weldable as long as surface contaminants are ‘minimized, 4.1.3 Welding Parameters, The data shown in Tables | through 7 are offered as a guide to develop welding schedules for uncoated carbon and low-alloy steels. ‘Welding parameters in these tables should be considered as starting points for the development of actual produc- tion welding schedules. The optimum welding schedules ‘may vary with different applications and with different machines, ‘The following sections are comments and discussions pertaining to the welding parameter data in these tables. ‘Additional comments and discussions applicable to car- bon and low-alloy steels as well as other metals are pre- sented separately in 4.7. 4.1.3.1 Electrodes. Resistance Welder Manufac- turers’ Association (RWMA) Group A, Class 2 elec- trodes (see Table 8) are generally recommended for these steels because this group of electrodes maintains rela- tively high strengths at elevated temperatures. They will hhave reasonable life when correctly used to weld these steels. These electrodes are copper-chromium or copper chromium-zirconium, and exhibit higher strengths and correspondingly reduced electrical conductivities than Class 1 copper electrodes. 3AWS C1.4MVC.1:2000 Table 1 Spot Welding Parameters for Low-Carbon Steel® [Nugget Diameter Etectode!? | Net Welding | Minimum | Miimamt | Minimum ‘mm (in.) Metal? Face | Electrode | Weld! Curent | Contact| Weld” | Shear Thickness | Diameter | Force | Time | (Approx) | Overlap | Spacing | Suensth? | Minimum movin) | _mm@in) | RNG») [Cycles] Amps | mmcin) | mmcin) | xNcb) |satsfactory) Setup 04 OOD | $76 0.187 | 1.78400) | 7 | as00 |r12(04H] 95037 | 142G2 | a1;01y | 457 O18 0.94002 | 475(0.187)] 2.00450) | 8 | 9500 |11:9/047| 127050) | .00(450) | 341 012) | #57 (0180) 0.99 (a030) | 635 0250) | 2.22500) | 9 | 10500 |13.0¢051)| 15.9063) | 245,350) | 361010 | 635025 doa fea) | 6330230) | 267600 | 9 | 11500 |13.51053)| 19.0:0.25) | 3.34030) | at cate | 635 0250) TEE Gas) | 35 250) | 3.11 200) | 10 | 12500 | 14.2406) | 21.6(085) | 4.11 920) | aiote) | 635 02s) 137 ss | $35 0250) | 3.34750 | 11 | 13000 | 15.0(05% | 239 (098) | 5.12(1150)] 48 (019) | 635 (0250) rao (ease) | 7280319) 3.56.@00) | 12 | 13500 | 155(01)] 25.41.00) | 6:01 «1350)| 5.1 020) | 9:98 oaI8) 133 (058) | 7:98 0:313)| 4.00(900) | 13 | 14000 | 16040463) | 27.0(1.06) | 7.12,1600)| 5310.21) | 794313» Tra tooeny | FeSO!) | 445 4000) | 4 | 15000 | 16.50.65) | 286.113) | £23.1850)| $8023) | 794 (0313) Dow one, | aes SBb200 | 16 | 16000] 17:3 (068)| 565 (125) | 10.23 23005] 6.4025) | 794 0313) 250 loan | £34 0322) | 623 400 | 18 | 17000 | 18.3 0.72)| 363 (1-44 |12.01 e700) | 6.6 (026) | 194 (0313) Fe BARD | 3.520375) 7.721600) | 20 | 18000 | 198(0.28)| 39.7 1.56) |15.35,3450)] 69027) | 95940375) 383 (0105) | 9.52(0378)] 8.01 (1800) | 23 | 19500 |21.3 (084) | 4291.6) | 1846,4150)| 9.1028) | 939 0379 208 120) | 9.52(0375)] 9.34 2100) | 26 | 21.000} 25:9(1.02)| 46.01.81 [22.24 5000)| 7161030) | 9:32 0379, (General Notes [Shapes that an be used ae: E = Troneated cone (45 dep bevel) A = Pointed B =Domed F = Radios ip ‘Ako see Figure 1 2. Forintemediate thickneses, fore, 3, Eletode materi: RWMA Clase 3. 4 Minimum weld spacings measored froma centerline to cemetne. 5. The dua within this ble was supped by com 6. Based on single-phase ac 60 Hz equipment 7, Based on 200 MP (30s) yo strength materia 4.1.3.2 Net Electrode Force. High-strength (HS) steels typically require higher electrode forces than low- strength, low-carbon steels. The higher forces are neces- sary to overcome the higher faying surface contact resis- tance of the HS steels and to compensate for their higher strengths. Additionally, the bulk resistance of HS steels is greater than for low-carbon steels, and the increase in clectrode force is used to promote proper heat balance. [HS steels may require clamping adjacent to the weld area in order to obtain proper joint fit-up, Inswlation should be used to prevent current shunting through the clamps. HS steels, because of their higher yield strengths, may expe. rience excessive spring-back after completion of the weld ifthe adjacent clamping force is not adequate. Ex- cessive spring-back may result in weld fracture. How- ever, electrodes should not be used as clamping tools to ‘overcome poor joint fit-up. 4.1.3.3 Hold Time. Typical hold time to solidify the weld nugget varies from 5-15 cycles for low-cerbon weld time, and cuenta be interpolated = members se represnts an average of typical parameters ued in industry, ‘and low-alloy steels. Some HS steels require very short ‘or no hold time in order to minimize embrittlement of the weld nugget. The hold time typical of low-strength, low- carbon steels may quench some HS steels too quickly. This condition is called “hold time sensitivity.” When ‘welding these steels, the welds should be checked for this characteristic, This can be done by increasing the hold time to 30 cycles and making another weld. After the weld is made, test the sample in a normal peel test and examine the weld area, If the weld exhibits inter- facial fracture, or results in a partial button or cracks are found in the metal, the material is “hold time sensitive.” 4.1.34 Temper Time. Medium-catbon and some HS stcels may require postweld heating in order to im- prove tie mechanical properties ofthe weld. This may be obtained by applying a separate tempering current in the weld schedule, The weld should be cooled to a tempera- ture below the critical temperature for martensite forma- tion before the application of the tempering current. The 4AWS C1.1M/G1.1:2000 "ods usaaag sump au0349 0) aus sy panes am span ucetpy “s "audi "vamp sponse ss aus aps salsuep aon in sepostay eet “S5UD VINA Busse apoE 1) Bay oap wes] yuna paises jo dK is wo pase “y ) ua 9 2930 “E SION BED & of POLO PEL Br we a w + a | 9 vt 0 9 #1 o 9 wenes + s © wen ss 4 s £ weose r 5 £ ro) dmas | Gomesnes Curyorz) SPA, (ap uns cup uuu wn ‘uu Zor oltuis x0 Paprays 2q on sossouyon, ous. P se wonRUIguIeD a $P19y 390 | J PIAN WwaoelDy mua unui oy (Car sz0) wu y9= pu jesniaves core) wu gz « : ley so10K> sak CJ s or Oh a oe 1181S UOqueD-Mo7 Jo} sidjoWeJed BuIpjaM Jods UONeSing zeigenAWS C1.1MC1.1:2000 Table 3 ‘Seam Welding Parameters for Low-Carbon Stee!!:? lecirode™ Wiath and Shape Minimum’ 18mm on a Contact RADIUS pains Tew ens ‘Thickness of Net Wats" a the Thinnest Blectrode Speed | Welds per Ss Piece Metal | Wm (ing, | Emmi). | “Force” | on time mimin | meter | Current | SH mm in) | min. max | tN Ab) | cyeles# | Cycles | cinvminy | in) | “Amps | =? 0250010] 95037 | 4600.18) ]i.78 40) | 2 1] 2007 | 59005) | 8000 | 95039 053(0021)| 951037 | 48(019) f2asiss0) | 2 2 | 19a | 47002) | 11000 | 11088 0.790031) 12.7100) | 6.4(025) |4.00(900) | 3 2 | rsa | 390c0) | 13000 | 12:7050, 4.02 (0040)| 12:7(0.50) | 641025) |asacoso) | 3 3 | 126 | 3500) | 15000 | 127050) 1.27 (0050)} 12.70.50) | 79,030 [3670050] 4 3 | 176m | 310@) | 16500 | 143 (036) 137 (0062)| 12.7050) | 791031) [s34(1200)| 4 4 | 16063) | 280 | 17500 | 159,083) 1-98 (0078)| 159/043) | 951037) [667 1500) 6 5 | r4qs | 2406) | 19000 | 175 0.69) 2.380084) 159(063) | 111048) |756(1700| 7 6 | 136» | 200.5)] 20000 | 190075) 2.770.108) 19.0103) | 127(030) |8670095)| 9 6 | 12@n | 2005) | 21000 | 206 0.31) 3.180.125) 19.0(0.75) | 1270030) |9.79(2200)| 11 7 | ras | ts0645)| 22000 | 2220087) (General Noes 1 Typrof seet_sat 1010, 2 Material shouldbe fe rom scale, oxides, pnt, prease, a i 3 Forthe eles with a radius fe, be ace wid is the same asthe clectode width, 4. Blecrode materi: RWMA Class 2 5 Forlarge assemblies, minimum contacting ovelap indicated shoul be increase by 30 percent 6 Based on single-phase a-c 60 He equipment 7 Welding speeds noted donot give a ea ight scam, fempering current should not remelt the weld nugget nor Teheat the weld above the austenitizing temperature 4.13.5 Weld Current. Compared with low- strength, low-carbon steels, HS steels have higher bulk resistivities, For this reason, HS steels may require lower ‘current levels than low-carbon steels of similar thickness in order to produce similar weld nugget diameters, 4.2 Coated Carbon and Low-Alloy Steels 422.1 Introduction, Metallic or nonmetallic coatings are applied to sheet steels primarily to improve the corro- sion resistance of the steel during serviee. These coat- ings, however, present some weldability concerns Coatings alter the contact resistance at the electrode-to. workpiece interface and faying surfaces. They generally require increased current, which may result in increased heating of the electrode. Coatings may cause rapid ero- sion of electrodes by wear, or by alloying with the elec- trode material. Electrode sticking due to this alloying can result in pitting of the electrode tip and rapid electrode face erosion. In addition, some alloying of the coating feSip meen erte thas ‘menarche on With the base metal may occur, which may alter corro- sion protection, Coated steel may give off fumes while being welded. Care should be taken to ensure proper ventilation to re- ‘move these fumes from the welding area, Ventilation is addressed in 10.9, 42.2 Types of Coating, The fllowing is list of var ious types of coatings used on steels along with some comments (0) Zine-Base. These costings are nomally applied citer by hot-dipping or by electrolytic deposition, (@) Zinc (commonly refered tos galvanized or clestogalvanized) (©) Zincaluminum (Zn =5 percent AD (©) Zinenikel (d) Chromium + chromium-oxide + zinc. (©) Zine-iron, @) Aluminum Base. (a) Type J aluminum (Al with 5-10 percent sil (©) Type 2 aluminum (pure Al. (© Aluminum.zine 45 percent Zn +15 percent Si) ‘on. 6‘AWS 61.11401.1:2000 Table 4 ‘Spot Welding Parameters for HSLA Stee! (ASTM A715, Grades 50 and 60) Minimum Yield Strengths 345 to 415 MPa (50 to 60 ksi) Minimum Nugget etectode'* Net Weiding | Minimum | Minimam | Minimum Meas | Face | Blecode | weld | Curent | ‘Contact | Weld | — Shear [Satisfactory] _Seup ‘Thickness | Diameter | Foree | Time | (Approx) | Overlap | Spacing? | Surength, | Diameter | Diameter mn.) | mm in) | KN) [Cycles?| Amps mm(iny | “kN Gb)” | mn) | mmtin) 051002] 4600.18) | 2.00(450) | 8 | 5600 [1124] 95030 | 211475) | 311 [4370.18 061 (0.024) 4.6(0.18) | 2.361530) | 8 | 6300 | 119(0.47| 127(050)| 2.36 (525) | 3.1 (0.12) [437 0.180) 0.76 (0.030) 6.4(0.25) | 285(640) | 9 | 7000 | 13.0¢031)| 159,063)| 343070) | 31 (012) [635 (0.250) 091 (6.026)| 6.40.25) | 3.11700) | 19 | 8100. | 135053)| 19.0 (0.75) | 4.83 (1085) | 46,018) [6.35 00.250) 1.09 (0.083) | 64 (025) | 3.69(830 | 11 | 8900. | 14.70.58) | 22.9(0.90)| $.76,1295)| 4.6,0.18) [6.35 (0.280) 1.35(0033)| 7.9031) | 45,1000] 13 | 10000} 15.70.62) | 2641.08 | 7.16 (1610) 4.60.18) |792(0.312) 1.63 (0.064) | 7.9031) | 5341200) 17 | 11100 | 16:8,0.66) | 29.70.17) | 11.07 2490) | 4.6 0:18) |792(0.312) 1.96 (0077)| 7.9031) | 6360430] 21 | 12100 | 18.00.71) | 35.1 1:38) | 14.37 2230) | 5.6 (022) |7.92(0.312) 2.36 (0.093)} 8.9035) | 7:70(1730)] 28 | 13.300 | 20.1 (0.79) 46.1 (1.58) | 1730 (3890) | 5.6 (022) |8'89.(0350) 2.87 (0.113)| 8910.35) | 9.342100) 38 | 14.500. | 20,3 (093) | 44.21.74) [2286 (5140) | 64 (025) [8.89 (0.350) 3.48 (0.137)} 8.90.35) [11122500] 51 | 15700 | 29.7 4.17) | 49.8 (1.96) | 26.47 (5950) | 6.4 (0.25) [8.89 (0350) General Nows 1 Shapes that canbe used are E—Truncatd cone (5-deg bevel) A—Pointed ‘Also see Figure 1 Hold ie—See 4.13. ara ae based on single-phase a 60 He eupment “Minimum wel spacing is measure fom ceneline wo centering. Electrode materi: RWMA Class 2 Forintemediate thicknesses, Frc and weld time maybe interpolated, Table 5 Spot Welding Parameters for HSLA Steel (ASTM A 2715, Grades 70 and 80) Minimum Yield Strength 485 to 550 MPa (70 to 80 ksi) Minimum Nugget Electrode] Net Welding | Minimum | Minimum | Minimam Metat® |" Foce | Electrode | Weld | Current | Contact’ | Weld. | Shear” |Satisfaciory| _ Sewup ‘Thickness | Diameter | Force | Time | (Approx.) | Overlap | spacing? | strata, | Diameter | Diameter mm in) mm(in) | _KN«b) [Cycles?] “Amps” | mm(n) | mmiin) | KN«lb) | mm) | mmGn) 051 002| 4600.18 | 200450 | 8 | 5300 [112044] 95@3] 236625) | 31.1 [457 (0.180) 061 (0.024) 4.6(0.18) | 2:36:53) | 8 | 6500 | 11.9(0.47)| 12.7050) | 2.89¢650) | 3.1 (0:12) |4'57 (0.180) 0.76 (0.030)} 4.6(0.18) | 2.85 (640) | 9 | 7000 | 130(051)| 15:9(063)| 4.40990) | 3.1 ¢0:12) |4'37(0.180) 0.91 (0.036) 6.4(0.25) | 3.11 (700) | 10 | 7900 | 135(053)| 19.0(075)| 621 01395)| ¥'6(0:18) |6.35 (0.250) 1.09 0.043) 6.4 (025) | 3.69(830) | 11 | 9000 | 14.70.58) | 22.9(0.90) | 7.41 (1665) | 4.6 (0.18) [6.35 (0.250) 1.35 0.053)| 64 (025) | 445(1000} 13, | 9900 | 15.7 062) | 264(1.04)| 921 2070) | 46.18) Jo3s (0250) 1.63 (0.064) | 6.4 (025) | 5.34(1200] 17 | 10700. | 16.8 0.66) 29.7 (1.17) | 14.63 (3290)| 4.6 (0.18) [6.35 (0250) 196(0.077)} 79031) | 6361430] 21 | 11 800 | 18.00.71) | 35:1 1.38) | 1837 4130)| $600.22) [79210312 2.36 (0.093)| 7.9031) | 7.701730} 28 | 12500 | 20.1 079) | 461 (1.58) | 22.42.5040) | 5.60.22) |2192(0.312) 2.87 (01113)| 89(0:35) | 9.342100] 38 | 13400 | 203 (0.93) | 44.21.74) | 20.36 (6600) | 6:4 (0.25) |s.89 (0.350) 3.48 (0137)] 8.90.35) [11.12.2500] 51_ | 14300} 29.71.17) | 49.8.1.96) | 33.81 (7600) | 6.4 (0.25) |8.89 (0.350) General Notes 1. Shapes that canbe used ae ETruncaed cone (5-de bevel) ‘A—Pointed ‘Alsos2e Figure | Minimum Hold time See 4133. Frey sow oe ih av eta based on single-phase ac 60 #2 eouipmen. ld spcng is measured from cern to centerline Etetrde mateial: RWMA Cass 2 For intermediate ickneses,frce and weld tine maybe interpolated, 1‘AWS C1.1MIC1.1 2000 Table 6 Spot Welding Parameters for HSLA Stee! (ASTM A 568, Minimum Yield Point 380 MPa [55 ksi]) Blectrode! Nugget Diameter Fiat Face | Net Minimum | Minimum? | Minimum ‘mm (in.) Meal | (Truncated | Bieevode | weit? | Welding | Contact | Weld” | shew ‘Thickness |” Tip) [Force | Time | Current | Overlap | Spacing | Strengin | Minimum mom (in)_| mmiin) | kN«tb) | Cyctes | Amps | mmiiny | mmtin | KN) |sausfactory] — Semp Darina | £20018) | 200c480 | 8 [sco Jrr2@4n! 950037 | 2.0005 | 31001 Jas7 olen po ioone) | £50248 | 238053 | | G100 | 1190.47) | 12.7(0530)) 222(500) | 31c010 457 (018) $30 (Ga30 | 64025) | 285,640) | 9 | 900 | 1304051)| 159(063)| 3.34050) | 36,a1s) lars iozsey Fp (ous | 84025) | 311.700) | 10 | 7700. |135(0330] 19.0075) «39 (1100)| Ae (O18) [635 0280) Tas tonss| $$(039) | 3620830 | 1 | 8700 | 1470058) | 22.9(090)| 5.78 (1300) | 4.80.19) |035(0250) 183 Gasp] 73030 | 4451000) 13 | 10.000 J 15.7062) }262¢1.03)| 67813205] 3302) lou ois) 153 (2068)| 796031 | 5.341200) 17 | 11500, | 168 (0.66) | 30.0(1:18 | 11°36 2600) | 61 024 {794 (0313 reel | eaeae | $36cis30/ 21 | 12100 | 178 (070) | 3581.37) | 14.23 22005] Gota29 794031 39 GARD | 8910.35) | 7701730) 27 | 13000. | 203 0.80 | 40.61.60) 16.90 3800)| 1.1 (028) [889 03509 Ja lois | 83039) | 9342100) 37 | 14200 | 23.60.93) | 44.44.15) | 20.24 (5000) 7.8 (031) [889 (0.380) 346 0157)| 891035) [1112 2500) 48 | 15600 | 31.21125) | 30.8 (200) | 2780(6250)| 8.61034) [8.49 (0800 Genera Note: 1. Eleevode material: RVMA Clas 2. 2. Based en single-phase 0 He equipment 3. Minimum weld Spacing is measured Ton centri to cote. (3) Lead-tin alloy (Teme coating). (4) Tin. (5) Zine-based primer. For single-side coated steel, the higher electrical resistance caused by the zinc-based primer can lead to short electrode life if the coating is facing the electrode. However, the bare stee| atthe faying {interface improves weldability (6) Organic composite. These coatings are applied to steels that have been metallically coated, and have under- gone a chromate treatment. An organic of organic-sili cate coating is the third and final layer. The composite ‘coatings are typically applied to one side of the steel sheet. Paint, vinyl, or other nonconducting organic coat- ings may prevent direct resistance welding. The compos- ite coatings with high electrical resistance can cause increased electrode wear when the coating is facing the electrode. (7) Metallic plating. Steels may be plated with ehro- mium, nickel, tin, zine, copper, or cadmium. Chromium and nickel platings have welding schedales similar to an equivalent gauge of uncoated steel; however, an adjust- ‘ment in welding current may be required. When welding plated stcels, care must be taken to provide adequate ven- tilation and remove any fumes which may form while welding. For example, cadmium-plated steels, or steels having cadmium-bearing coatings form toxic cadmium fumes during welding. Generally, welding alters the plat- ing in the area of the weld, (8) Phosphate. Phosphate coatings have high electr- cal resistance and phosphate-coated steels are difficult 10 weld. A pulsation or upslope of welding current may be re- uired to break through some of the coatings above because of their high clectrical resistance. 4.2.3 Surface Conditions. Prior t welding, the workpiece surface should be free of contaminants which may adversely affect weld quality. Zine-coated steels can oxidize to form zinc oxide, oF ‘white rust, White rust is a wet storage stain, and can best be prevented by storing the coated steels in dry areas. White rust is @ nonconducting layer which can prevent the resistance welding of coated steel. Removal of the white rust by wire brushing or chemical cleaning prior to welding is highly recommended, Aluminum-coated steel may require wire brushing or chemical cleaning prior to welding. In some instances, the tenacious aluminum oxide layer should be removed. ‘to minimize expulsion and electrode tip pick-up of alu- minum. Care must be exercised during cleaning opera- tions to remove the aluminum 0% the aluminum coating layer only and not 4.2.4 Welding Parameters. The data shown in Tables 9 through 12 are offered as a guide to develop welding Schedules for coated, low-strength low-carbon and 8AWS C1.11/01.1:2000 “sorenduo> fot wor peurego meg 9 uauainbs 2 09 ‘ppm use yo ny tina puns 2 sesuadutos oy Lye 99 poou suonMaSa “sepanzais om) us “CaO VIUAQH TPo=IeU aponDoE ‘suo-o1u gge Bupssow you soumsas auc apis wngoo1paua|y asntaKt zo Pell! oa Pino USAT Gssoovi iow ziorss Jioszises] usorcee] se | core | 06 | ost | se |tcosrzove|(oor ese | exorest | oo s'se | serovar! susavs rac} esos | se | oscet | or | se | ot [toners | ovost Jaros |terssi|csomee7 susavs wzo69 | (one 991 rose | omar fevoest| ror] se | oe |e | £ feoossi961 | coviost [teroze | oso ezt | e100 90) peamuon siue ays Perr soe] 9 | ore | os | oi | sr Joosmzvuc|ooirse |ermee: | oonrse |cscrwere oss ays (ssw ort we sn ze9s 269 | orcrorsi tepoesi| es | ooset | or | oe | at ftoosncroe! wares ceowesi | asou oe orseays. 1 Ga virs [ocovs}ororn| ss | oor |» | a | + | aosoce | west firmer |oswce se] cos avs ‘wansa pa (ssoovifiorwensos |toscses] usmere| 98 | ooze | os | ov | sr Jeoassrerseloorese | terest | oor rsc|(scro ere oreravs 069 | onerous forvrse| rossi} ce | oaset fosos1 | verse [seo 061 | eso0)661 orevavs ost cososi | crore | eo) 6st | aco 6x0) paanesuon| arcravs ‘ou Et +9 one en [oct avs 008 £1 +9 1 VS oe 79 1 avs 0091 79 avs duay (cup wa ad, Cody Bauig wang soe oroepes| unary tuna | oun taduay Pe fey mH 98108}g UOgieg-wiN}pe; Pue AojIy-Mo7 40} s1\oUIEIeq BuIpleM 10dg zeigenAWS C1.1M/C1.1:2000, Table 8 Electrode Materials for Resistance Welding Chass Group A—Copper Base Alloys Chass 1 Cadmium copper 1.16200 118200 Zirconium copper 1.15000 Chass2 Chromium copper 2.18200 (Chromium zirconium copper 218150 Chass 3 Beryllium copper (Co) 3.17500 Beryllium copper (Ni) 3.17510 Beryllium free 3.18000 Class Beryllium copper 4.17200 Class 5 ‘Aluminum beonze 5.95300 Group B—Refractory Metal or Refractory Metal Composites Class 10 ‘Copper tungsten (45% Cu/S5% W) 10.74450 Chass 11 Copper tungsten (25% Cw75% W) 174400 Cass 12 ‘Copper tungsten (20% Cu/BO% W) 1274350 Class 13 ‘Tungsten 13.74300 Cass 14 Molybdenum 14.4230 Group C—Specilty Materials Class 20) Dispersion strengthened copper 20.15760 HSLA steels. The following sections are comments and ments and discussions applicable to carbon and low- alloy steels as well as other metals are presented sepa- rately in 4.7, 4.24.1 Electrodes (See Table 8) 4.24,1.1 Electrode Material, Industry uses several electrode materials for the resistance welding of coated steels. The individual application, including size, shape, materials being welded and weld schedule, has dictated different material selections. These electrode materials are selected for the following characteristics and properties: RWMA Group A, Class 1, materials are relatively weak electrode materials, but they exhibit the highest conductivity. They can conduet the increased currents as- sociated with coated steels and cool the face quicker, which can retard alloying between the coating and the electrode, RWMA Group A, Class 2, materials are used for welding coated steel because of their higher strength, which better matches the strength of steel than Class 1, ‘These materials have increased resistance to annealing (softening) and thus, mushrooming is retarded, RWMA Group C, Class 20, dispersion strengthened copper electrode usage has increased with the introduec- tion of new coatings and expanded use of traditional gel- vanized coated steels. These electrodes have strength and conductivity properties similar to Class 2 materials, In addition, they exhibit greater resistance to annealing (softening) and are noted for increased resistance 10 sticking to coated material. 4241.2 Electrode Shape, There are several standard and nonstandard clectrode shapes available (see Figure 1), Seam welding electrode configurations are available in wheel form, Wire-wheel seam welding, Which uses a continuously fed wire as an intermediate electrode between the electrode wheel and the work- Piece, is also an acceptable configuration. freeonesAWS C1.4M/C1.1:2000 Table 9 Spot Welding Parameters for Galvanized Low-Carbon Steel':7 Electrode! Nugget Diameters! Net Weld | Minimum | Mtinimam Minimum Metal! | Face Electrode | Wetd?| Curent | Contact | Weld” | Minimum Shear Thickness | Diameter Force | Time |(Approx.] Overlap | Spacing [Satisfactory] Sotup | Sueseth min) | mméin) | stapet | kN Gb) [cycles] Amps | mmiiny | mmcin) | mma | mm n> | ENG patna se GteD/ ABE [211470 | 10 | 10900 fii2@40] 95037] 3001 |a6cim) laaGa O96 (omnes oD] ABE [2340530 | 11 | 11 500 {119,047} 1591063) | 33,0113) Jasco) 200 (aon) 089 (000) (o PAD]ABE |256(580) | 12 | 12300 |119(047] 1391068) 3640.18) [54 (020)| as6 600) Tb tonnes 2g 2259] ABBE |2.78,620) | 13. | 13500 |135(053)| 1901073) 41 (O18) e405] saved 114 os l eae Oat] ABE-E)311(700) | 13 | 14 100 [1355 (053) 19.00.75)| 430.19 [ea (025)| a1 oom Tar fos 35 (9250) A-B-ELE|338(950) | 14 | 14800 [15:0 (039) 203 (098) | 48 (0.19) [ea 099] siz (ray 1n0 .0s9)| 798 oat] APBE-E|356 (800 | 16 J 15 600 |15.0(0.39)| 203 (0.94) 5.1 (0.20) {79 0319| gor (1350) 152 (0.000) Foe ap] AB EE) 445.4000] 17 | 16200 |16.010.6)) 27.0(1.06)| 53102 |79(031)| 212160 178 (ool Fan Oat] A:B EE) 456(1030)] 18 | 17000 |16:0(083)| 2701.08) | 3.6023 [79 (0319| gas ieey 203 (0080)| Foe aay] APB EE] 545 (1230/22 | 18 800 16.8 a66)| 30.00.18) | 61 (225 {79(031)|1023 e300) 335 2080) 68 ona) ASE E| 1200380] 25 | 19.600 |18:3072)| 349(137)| 66,026) [79031] i201 mom Far oes) ae wd) BEE) 67 500)] 31 | 20400 |19°8 0.7) 39.7(136)| 69.02 [930371393 corso, Fos 9 oo O39] ABE] 767 0720)] 35 | 22.000 [21.3 (08%) 3271.68) | 9-1 028) [9.503 eae cris 3.05 (0.120)|952(0375)/ A. B.E,F]9.24(2100)] 42 | 24000 |22:4(088)| «6011 81 | 761030) [93030 299 ooo Gener Noes ‘Welding parameters re based on single-phase 60 Hz equipment, ‘Wielding parameters are aplicable to welding two sack jis of one-sided or two sited galvanized low-carbon see 2 3, Welding parameters are applicable when sing electrode materi incloded in RWMA Clases 1,2, and 20. + mee ae ian ua kaos of eset big Wel Inte ase of wen wo she of ie icknenes eh welding parameters forthe thinner set, 5. Nugget ameter a sted a ‘Hie minimum diameter that is recommended to be considered astifctny wed rea name moet ance at i ecomnende in ting yp wed ton pode ues th consistent spas saisary ‘weld auggtciamcter fra given numb af reduction welds { Bectrode shape td incde. Aponte, B-domed, Erased, Fase. Figure 1 shows hese shpes, 7 These recommendations are sed on awl weld schedules represating conned essanes welling equipment supplies nd wes 4.2.4.1.3 Electrode Life. Electrode life can be fined as the number of welds that ean be made with a pair of electrodes and maintain weld button diameters above a specified minimum value. Coated steel typically shortens electrode life more than uncoated stecl. The coating may alloy with the cop- Per electrode and result in electrode sticking and pitting of the electrode face. Coatings that contain zinc, alumi. ‘hum, tin, or cadmium can alloy easily with the copper lectrodes. Different coatings result in different electrode ‘wear characteristics, 4.2.4.2 Net Electrode Force. Coated steels typi cally require higher electrode forces than uncoated steels. This is especially true for steels with multilayered ‘coatings or primers. Phosphate coatings have very high clectrical resistances and may prevent the passage of cur- rent at low electrode forces. Steels with thin phosphate ‘coatings can be welded satisfactorily; however, even at higher electrode forces, slight variations in phosphate coating thickness can result in inconsistent weld quality. Coated HS steels typically require higher forves than ‘coated low-strength, low-carbon steels (See 4.1.3.2). 4.24.3 Weld Time. Coated steel requires longer weld time than uncoated steel. Weld time may need to be increased as the coating thickness increases. 4.2.44 Hold Time. Short hold time may be neces- sary for coated steels in order to reduce electrode stick- ing, Coated HS steels may require very low hold time (ee 4.1.3.3), 4.24.8 Temper Time. Temper time may be incor- porated into the welding schedule when welding coated HS stecls and medium-carbon steels. These stecls may ‘require heat treatment after being welded in order to im- prove the mechanical properties of the weld. After com- leting the weld, the welding cycle will go through a {quench time (sometimes referred to as the cool time), uring which no current flows through the workpiece, and the weld is rapidly cooled by the electrodes. The tem. per time follows the quench time, Tempering is obtainedAWS C1.1MIC1.1:2000 Table 10 Spot Welding Parameters for Galvannealed Low-Carbon Stee!".” Electrode? Nugget Diameters? Net Weld | Minimum | Minima Minimum Metal! | Face Elcctrode | Wetd?} Current | Contact| Weld | Minimum Shear Thickness | Diameter Bre) ne J(ApEre%9| Overlap | Spacing. ISaiafctayl Setop | sueseen Smin) | mmtiny | share | 1b) [cytes] Amps” | mmiing | mance [este mm (in| kN db) ae (ona o9g 220] 4-8. [ier Gan | 6 | e000 [i2(an] a3 oan 25 (0.10) [5.1 (0.20) 1.42 G20) Ose (ods) oe G20] ABE [1.7840 | 7 | S00 |irdan| issias 3.1 (0.12) [5.1 0.20)! 2.00 cas dab ours) 08 0200] .B.e l2.0eas0 | 8 | 10300 firs @an| isswen 3.60.18) |5:1(0.20)} 2°56 (580), Tan taoaay|O3g 0230] BEE [2.67 600) | 9 | 11500 |isstosH| tows 4.1 0.16) [6.4 (0.25)] 3.34 (750) 5c (o01| O35 O50] A-B-EE|2.89.650 | 10 | 12500 |1335(053)| 12007 480.19) [6.4 0.25)| 4.11 (020) 137.8 | os (0250] A:B.EF|336(750) | 11 | 13000 {is0(059)] 239 95 5.1(020) [6.4 (0.25)) $112.(1150) 120 (0059794 Os] AEEE|356.800) | 12 | 14000 |is01039)| 239095 5.6 (0.22) |7.8 0:31)| 6.01 (1350) 153 o0en/ pat O31] A:B.EF|400,900) | 13 | 14500 |tentnen| a70(ney 6.1024) |78031)] 7.12 (1600) Leon l 794 O31] ABE |445 4001 14 | 15000 |icotoss)| arotto 6610.26) |78(0.31)| 823 (1850) 203 (0080/94 a RB EE [53400200] 16 | 16300 |16810.60)| 30026 | Seas 7.8 (0.31) 10.23 (2300), 355 (ose) 3p O383)] ABEL [5781300] 18 | 17500 fissiazy| seo 7.4 (0.29) {78 (031){12.01 (2700) 3er oo ose 2323] 8B E [667 1500] 20 | 19000 |198 10.78)| 39. eap 8.1 (0.32) [95 (0.37)|15.35 aso) Fos etay 933 0329] A BEF [8010800] 23 | 20000 |21 5 aml 27h 8.40.33) |9.5(0.37)|18.46 (4150) 205 10120)}952.0375)| 4.8.£,F]9.34(2100)] 26 | 21000 [22.4 (088)| se0L Sh 8.6(0.34) |95 (0.37)|22.24 (5000) General Notes ‘Welding parameters re baci on sagle-phase ae 60 Hz eauipcne Welding parameters ar applicable wher parameters forthe thinner bee, 5. Nugget diameters ae ted ing elctoe miterialsncaded in RWMA Classes 1,2 and 20, parame genet Stil thickness fhe sb beng weed. late ts of wedeg ie deo eet thicknesses, use the welling BS minimum Gane hat recommended tbe conser a sasciory weld hint aim setup nugget diameter tha resonunence, weld nugget ciamneter fora given number of potion by applying an additional current, the magnitude of which is a fractional value of the original welding eur- ‘ent, The weld should be cooled to a temperature below the critical temperature for martensite formation before ‘pplication of the tempering current. The tempering cur. ‘ent must not remelt the weld nugget, and should not re- heat the weld above the austenitizing temperature, Proper setup for any particular alloy may require considerable adjustment of the quench and temper times, and of the temper current level for best results 4.2.4.6 Welding Current. Coated steels typically require higher currents than uncoated steels. The pres- ence of molten coatings at the faying surfaces during welding provides a shunting path for the current, The ‘coating is displaced from the weld area after melting, and surrounds the weld nugget in the form of an annular rng ‘The molten coating has a lower electrical resistance than the base metal. Current shunting through the annular ring ‘of molten coating results in a decrease in current density A ie a ag for the weld nugget. For this reason, increased coating ‘weights may require higher welding current or longer ‘eld time, or both. HS steels have higher bulk electrical resistivities than low-carbon steels. For this reason, coated HS steels may require lower current levels than coated low-carbon steels of similar thickness to produce similar nugget diameters, ‘Most coatings increase the area of contact with the electrode face, The increased contact area results in de. creased current density as compared to uncoated stec!, ‘The higher currents required for welding coated steels can lower the electrode life due to increased electrode heating. The welding current working envelope (lobe), for coated steel is narrower than that for uncoated steel, Zine- and zine-alloy coated steels require higher cur- rent than uncoated steels Cadminm- and tin-coated steels requite welding Schedules similar to 2ine-coated steels, but may require lower currents. Aluminum- and aluminum-alley coated 2‘AWS C1.1801.1:2000 Table 11 Spot Welding Parameters for Galvanized HSLA Steel'.” Minimum Yield Strengths 345, 415, 480, 550, and 620 MPa (50, 60, 70, 80, and 90 ksi) Wed Gover] Miso Tee ine? soe | Meine ove Simo, Electrode? 480, 550, | mmr) . wer | [saa cobs | CLL | Mis Met | _ Face Beets Pee| Goand] o.ao, | SET" | spacing | stim Thies | DES Fare. [ne | sian lonasony| SL, | Sete | Minima | tmnt) | mtn) | sh | ana [cite] ue [ons iS RNa See, 33 GaanI ER GIEDIAR E|Btoasn | 10) va0] —T900-TTiway open Te gaziom/sreian|aee |G | to | $$ | fan [Haei| goer] se [sen grecosoleds ian |cae [eat | 1 | Som | $6 [120%] 830000 33015 [tei seiaasless 250) A8.Ee| sem | te | aro | sbi [49087] 82060) Sotto [sero ‘gronipleseozp/ ARE el oon) | 13 | Haye | ipa [133053183079] 110 |actaay ‘onsesiaolaperliain | 5 | inam | (rae |i8s05|830%5| 430019 |eauaa5 enn eieaa/ABErfsene | te | am | (10 [ISOS 8@80| 4800 leans tabs 180313] REr|tsstow| 15 | 2am | faaee [158059 [2889] 5120 [7a'0a tsetomn/7Setoaig/ARErlsietian| ty | Som | [ty |fesioen [269100] $3003) [1939 Lawmogieas/AREFlseoia@| 2 | 135m | jan |1ee'0e) [269('00| 300023 [F903 SOMO SeMSIS}AREFIeswii9y| 3 | (37m | lea | e8(0a9 [e048] cr 038 79.035 Bom oan IAREr|Eo1 Gaon] a | les | (oa [Meer |MaUan| S20026 [1343p Tojowoloszoxs/Aaerlaiwinsy| 38 | team | iste [282 [26039] e9tozn [astaan seunolsaass]Aner|smaiy| & | am | tony [mates [saz tes] 11035 535 General Notes Tictng Feramets are pliable to welding wo sack ins of nese or esd avai hghatength ow-aoy set Welding paramcters are basd on single-phase a 0 Hi equipent elting parameters ae applicable wher using elecode miter ineluded in RWMA Clases 1,2 ané 2 dae fr raat tne of estes beng Wel Ine cn of wing best of ioe hicks, the welding patumeters fr the thane shes. 15. Nugget diameters ate ised as th minimum diameter that recommended tobe considered aif weld Wed mugger dam a came tt ecommenfedn ting p 8 wel sono produce mpgs th conse spa he safacry weld augge diameter fora given numberof production wales $F aes ed inca: Aponte, B domed, Eran, F—radise Figure | sos thse shops, 7 Thesecommrdains ae bast o aie weld cede oes ecunmerdaons om eee sipmey spp andar Table 12 ‘Seam Welding Parameters for Galvanized Low-Carbon Steel’ Electrode? Net | Weld | weld | Weiding Minimum’ Meu! | Wheel Body | Contact’ | Blectrode | On | ‘ont ‘Thickness | Width | Face Width | Force | Time | time min) | _mm¢iny | _mm¢ny | nab | cyctes | cycles 025 (010) |” 9.52 (0375) | 476018) | 22 (300) 053 (0.021) | 91520375) | 4:76 0.187) | 27 (600) 0.78 (0.031) | 12:70 (0500) | 6.35 (0250) | 40 (900), 1.02 0.040) | 12.70 (0.500) | 635 (0.250) | 4.9 (1100) 1.27 (0.050) | 12.70 (0.500) | 7.94 (0313) | 5.8 1300) 1.57 (0.062) | 12:70 (0500) | 7.94 (0313) | 6.7 (1300) 1.98 0.078) | 15:88 (0.625) | 9.52(0375) | 316.1700) 2.39 (0.094) | 15.88 (0.825) | 11.11 (0437) | 83 (1900) 2.77 (0.108) | 19.05 (0.750) | 12.70 (0500) | 93 (2100) 3.18 (0.125) | 19.05 (0.750) | 12.70.0.500) | 1022300) | 1 General Notes J) Welding parameters are splicabl for seam weliag low-carbon galvanized ste, 23 Melding parameters we apliable wsing elecuode materials included in RWMA Classes, 2 an 20. 3. Forge assemblies, the minimum contacting overlap should be increred oe, Td nese gi ele ef at Tce With eel es lero cps A alernatve is 75 mim (3 in) rade cot fice ‘would be across the entre wheel body width Welds per | Welding | “Contact Meter | Current | Overlap Gin) | Amps | mmtin) 381 (15) | 10000 | 930.37) 30512) | 13000 | 11.1 (044) 2540) | 15000 | 1420056) 2391) | 17000 | 142.036) 22918) | 19000 | 14.2(036) 1780) | 21000 | 160,063) 13266) | 22500 | 17.5 (0.69) 140655) | 24000 | 1900.75) 1276) | 25000 | 206(081) 11443) | 26000 | 222 (088) 3 Pra arden hs ‘SuotexoUoY tL, wanesAWS €1.1MiC1.1:2000 | ee TYPE “8 DOME a Tee: Far TYPE“AY POINTED Figure I—Standard RWMA Nose or steels may require higher current compared to zinc. Coated and uncoated steels. Aluminum-zine-coated stecls require currents slightly less than for zinc-coated steels. ;pot welding schedules for 2ine-based primer and or. Banic composite coated steels are similar to those for me- tallic-coated steels, but may require lower welding currents, Series or paraliel welding may be difficult for coated steels. Secondary circuit variations make it difficult to control weld quality, due to nonuniform metal conditions and electrode deterioration at the paired weld locations, In addition, series welding relies on the workpiece to conduct weld current from one electrode to the other, which can prove difficult with coated stecls. 4.2.5 Seam Welding. Seam welding coated steel re- uires more control over welding conditions than spot Welding. Proper control is necessary at higher speeds Since the weld is not contained by the electrode force. Excessive welding speeds and high currents can cause ‘racking in resistance seam welds. 43. Aluminum Alloys 4.3.1 Introduction. The resistance welding of alumi ‘pum and eluminum alloys is considerably different from other metals due to the physical and chemical properties described below (2) Aluminam and its alloys have substantially higher thermal and electrical conductivities than most materials that are resistance welded. This necessitates the use of higher welding current and shorter welding time. WW TYPE *D* OFFSET TYPE TRUNCATED TYPE“ RADIUS ip Geometries of Spot Welding Electrodes @) Aluminum has a narrow plastic temperature ‘ange. This and its high thermal expansion and contrac- tion may require the use of special weld force application Sequences utilizing rapid follow up, along with low iner- tia equipment for some applications ) Aluminum readily oxidizes on the surface, pro ucing a high and inconsistent resistance. Removal of this oxide requires a chemical or mechanical cleaning process, (4) Aluminum alloys fall into two general classifica tions, heat treatable and non-heat treatable. The non-heat treatable alloys may be hardened by cold working to some degree. Table 13 shows the alloy designation groups and major alloying elements. An indication is also given Table 13 Basic Aluminum Alloy Groups Major Alloying Blements 99.0% Min. Aluminum Copper ‘Manganese Silicon Magnesium Magnesium and Siticon Zine (General Notes 1 Aluminum Association designations. 2. Heavseuble alloys, “44s to whether the alloy designation is considered heat treatable. In general, the high-strength heat treatable al- Joys (2000, 6000, and 7000 series) have a greater ten- deney toward weld cracking and porosity than other alloys. (5) The temper of an aluminum alloy influences its weldability, with the soft tempers being generally more difficult to weld. Deformation under the electrode force {causes variations in current and force distribution that can result in inconsistent weld strength (6) A heat treatable aluminum alloy of a given temper may have a wide range of bulk electrical conductivity. ‘This can cause inconsistent welds with inadequate size or Penetration, Heat treating conditions should be closely ™monitored to control this condition ‘The weldability of various alloys and tempers in simi- Jar and dissimilar combinations is shown in Table 14 43.2 Surface Condition. The high surface resistance of aluminum and its alloys as received from the mill is due to the presence of a film of aluminum oxide and other contaminants from the rolling or extruding process. ‘This surface resistance is nonuniform and, in most eases, Prevents consistent weld strength and quality, The preweld cleaning should yield a clean surface of uniform electrical resistance. This surface will reduce variations in welding heat at the joint interface, and improve weld consistency. The parts should be welded as soon as possi- ble after cleaning. The acceptable holding period, or lapsed time between cleaning and welding, may vary from a few hours to 48 hours, or more, depending on the cleaning process used, cleanliness of the shop, the partic lar alloy, and other factors. ‘The surface may be cleaned, either chemically or me- cchanically, as described below: (2) Chemical Cleaning, The chemical solution clean- ing process is desirable for large production volumes, ‘Several steps are involved in the cleaning. A non-etching alkaline cleaning solution should be used fist to remove hheavy oils or grease, followed by a water rinse. Use pre~ caution when handling alkaline (caustic) solutions. They ‘can cause chemical burns and violent chemical reactions can result when mixed with acids, Before use, read and understand the manufacturer's instructions, Material Safety Data Sheets (MSDSs), and your employer's safety practices. The next step is immersion in a solution to re- ‘move the oxide film followed by a water rinse. The final step should be drying with forced air with or without heat. ‘The chemical solutions should be maintained at the Droper strengths to ensure satisfactory surface prepara- tion. The concentration may be determined by titration, and additions of chemicals to the solutions should be ‘made when necessary. The cleaning effectiveness of the Por oan octets Sonos say atten AWS C1. 1MC1.1:2000 solutions can be adversely affected by contamination, Contaminated solutions should be drained and replaced, ‘The principal advantages of chemical cleaning are Jow unit cost large production capacity, and uniform re- sults. The principal disadvantages are high capital invest ment, exacting controls, and the cost and difficulty of waste disposal, (2) Mechanical Cleaning. The use of mechanical Cleaning is generally restricted to small production quan- Uities or isolated spots on large pieces where it is not ‘necessary or economical to clean the entire piece. Me- chanical cleaning is recommended when lap joints are ‘resent that can entrap chemical solutions. A precleaner, such as a vapor degreascr or alkaline so- lution, is usually necessary to remove foreign substances prior to mechanical cleaning. The surface to be cleaned may be abraded by a stainless steel wire wheel, abrasive loth, or abrasive-impregnated nylon wheel. Wire brush bristles should not exceed 0.13 min (0,005 in.) diameter, and abrasive wheels or paper should not be coarser than 240 grit or the surface can become too coarse. Residual particles from the abrading process must be removed prior to welding. The principal advantages of mechanical cleaning are low capital investment and the ease of cleaning localized areas. The principal disadvantages are high unit cost, be- ‘cause this process is generally a hand operation, and the difficulty of assuring uniform cleaning, Automated equipment able to clean large sheets can eliminate some of these disadvantages. 4.3.3 Welding Parameters. The data shown in Tables 14 through 19 are offered as a guide to developing spot welding schedules for aluminum and its alloys. With the number of variables involved, itis impractical to specify welding parameters for every condition or combination, The parameters presented are for the most commonly Welded alloys and thicknesses. Although no scam welding data are given, seam welding parameters can be devel- ‘ped. Soine of these spot welding data can be used in de- veloping the seam welding schedules because of the similarity ofthe two processes. Higher currents are gener ally needed in seam welding to overcome the effect of cur- ‘ent shunting through previously formed welds. Projection ‘welding of aluminum and its alloys is not recommended. because of their narrow plastic temperature ranges, ‘The following sections are comments and discussions Pertaining to the welding schedule data in these tables, Additional comments and discussions applicable to alu ‘minum alloys as well as well as other metals are pre- sented separately in 4.7. 43.3.1 Electrodes. RWMA Group A, Class 1, copper electrodes are the most commonly used for resis tance welding aluminum and its alloys, RWMA Class 1 Is‘AWS C1.1M/C:.1:2000 (p2nupuos) 19 19 1219 1D 1D 1D vaca taza ce ta ota Iv_iv fv oy iy Iv ev SEH-SEH-veH-ZeH-9ses 19 1D 1D ta ota ia Ev ev vy, o-oses to % 19 (9 19 %9 19 to 12 19 1D 12 19 19 za vq ca za ca za za ca taza za ca cae cv tv iv iv tv zy zy ev Ivey ev EV Iv Ev _ senseH-ven-cen-csos ar) ro 19 iF} tT 19 1D za ca caoca ca va ca ca ev _ev fv py. ey py EV by ozsos Ome) 1 1 12 1 mecoeao ta ce ve ca ta va ca ta ota ly tv iy Iv_ev ev Ev IV ev _serornencenosos 112 tt 1D 19 1D za ze ta ora za za ota orosos fv ev ev by, bY ry ev 1219 1 oar) 1 > za oca ca te ca ca a ty iy Iv_+¥ ev v SEH-OCH-FeH-ZeH-Pooe 1D 19 1 Par) 1 2 ca ta za za ze ca ia aie o-v00e ev_ev ev Ev py py ev eV PV. 19 19 19 119 rar) 1D SiSTIPIH-ZIR-EODE a ca ca vaca za 1a a ota Iv tw pv Ive Evy Vv EV siboureptie-crito0r1 119 Io 119 119 2 19 o-E00E ca ca ca za za ia 1a a ora ev _Ev_opy fv Pv, ev ev. oor a er pao oH fouy be on sen sar 8eH sen on eb we oe SEH eH oe ou ok Pe Sue PHS Pee vel vee peg od Sk PDE mL EHS ce SE zee SUL SLOL_£909 1909 Wor _FeOc PIO _IOZ OSES 9SES ZSOS ZSOS OSOS OG0S POE OVE OOII OOTT Fi (sseuxoiy jenby uo paseg) shojjy winuywnyy Jo suoHeUIqUOD pasn AJUOWIWIOD 40} WUD AU|IGEPIOM eoUEIsISEy bh agen 16AWS C1.1MC1.1:2000 “ep wotoyyso asnas99 24 9 ‘uns suse yo aun owas 040 goo Kor 20 payaso ninjnun sp pn "MW amd se pood se ou sucz pom Jo sours uolsan) tow mated nbs suor pram Je aumsias vanes ‘woo: 0 aaumSIs ‘fe atssuo> pr punos aye a spon Sutuo;oeé eruoour ss font ye “Aujuags ou spony sats toe uso urs ‘0a pam a}}809 AD of or oo ea 4 pap rea sa Ho papa aq ueo pur pon sasaead edad ne spam ood ay ‘suas sung 98s apy e ano apa a Ge plan pons ¢ utpan jo 303-y SS1N D 19 t 1) 15 i> 91> @> iF) za ca za ve ca ca ta fa za iv tv tv tv cv ty tv cy zy 94-5101 pHIa\y wto tt 19 t9 19 e> rz) ze ta za ca ca fa ta ca za zy cv cv tv ty iv tv ty zy ousuoe 12 2 19 19 1D ta 1D 2a 19491913 1a 1 SS TS ig f@ t@ ta ca ce ca za ca ca ta ta ca ta te ie fp fp ty Viv iy iv zy cv zy iv ev iv ev iv cy re eo ia fe 94-51-0909 1222 19 12 12 2a 1D a 1919 1a 1a 19 13 oS ga fa a ca va ca ca ce ca ca ca ta ta ta ta ta te fo iv av «wv cv ey ty cv iv iv ev iv ev iv ey ie ee fa Ze 91-n1-1900 19 t9 1919 1D to 19 to iF) 1a 1D za va ova ca ta ca ca ta za za ta iv tv tv tv cv ty tv cy ze PV FY pbevecozpmey tw co tt) £9 to | su 2p gum Keo 61 Kce0)s'6 |iszorr9 |isc0)¥9 |Isc0) ¥9 | wD] sprem Jo smoy uaonreq EOS Jucoss [UEoor MEd |store [ecov9 | IBN | ys>mIC UMAR \si:0) 06 ‘0ez1\(0¢0) et] wwWOD: ued Koso) ez (e086 fucose | sw Pram wn (oro | eco | soo | zoo | io | cup SOUL wOUS zr | iso | two | iso | iro | juw sfolty sii Pue uinujwinty 40 spjeyA Jo SMoY UBSMIeq BoUEISIC pu ‘de}16N0 ‘eoUEISIG a6py ‘Buloedg plom iods papuauiuiooey st edeL 18AWS G1.1MIG1.1:2000 Table 16 Spot Welding Parameters for Aluminum Alloys on Standard Single-Phase A-C Type Equipment? Electrode Diameter and Shape! a RADIUS PH Radios Welding Weiding? Sheet sam fin) NetBecrode | Curent Time Thickness D Force (Weld) | Approx pore. mm (in) mmm (in) | Top Bleewode [Bowom Blecode| EN (b) ‘Amps (Cyetes) oai@oig | 159063) 1 Flat 12 G20) 15000 4 asi 002) | 15908) 1 Fla 151 G40) 18000 5 oss (0025) | 159°063) 2 Fla 173.690) 21 800 6 ogi oom) | 159063) 2 Fla 222 (500) 26.000 7 4.02(0.040) | 159,063) 3 Flat 2.57 (600) 30700 3 1270030) | 159(063) 3 Flat 2.96 (660) 33000 8 160(0.063) | 159(063) 3 Fla 3.34 030) 35 800 10 1eo@o7) | 159(063) a 4 3.56 (800) 35 000 0 203 (0.080) | 222087) 4 4 3.83 (60) 441800 0 22910090) | 220087, 6 6 5.23 (930) 46000 2 254(0.100) | 2221087) 6 6 46700050) | $6000 15 aise) | 22087 6 6 5.781300 | 76000 5 (General Notes: 1. Blecuode material: RWMA Class 2: Types of unin ally: 1100+H12-H18, 3003 HI2H-HI8, 3004 H32-H58, 5052 132-13, 5050-52-38, 5356-H52-HB8, 6D61-T4-T6, €063-15-76. 3, COO He equipment ‘copper has high electrical and thermal conductivities but is not heat treatable. If higher strength electrodes are needed, RWMA Group A, Class 2, copper electrodes may be used. The lower electrical and thermal conduetiv- ities ofthe Class 2 copper alloy makes it less suitable for Welding aluminum except in those cases requiring higher clectrode strength or in combination with Class 1 elec- trodes to control weld penetration in dissimilar metal or thickness combinations. 4.3.3.2 Net Electrode Force. Generally, the lower strength, non-heat treatable aluminum alloys require less electrode force than do the higher strength heat treatable alloys. ‘Aluminum has higher shrinkage upon solidification than steel. Use of a low-inertia, low-friction welding hhead assures rapid follow-up to reduce weld defects. In seam welding, higher quality welds are produced with indexing electrode wheels rather than with wheels turn- ing during welding. ‘The variable force cycle, in which the weld is made at 2 low force, followed by application of a carefully timed ne ae 9 higher force, is used to improve the weld soundness of some aluminum alloys during the solidification of the ‘weld. The timing of application of forging force is very ical. If applied too late, the weld will have already so- lidified, and no improvement will result If applied too soon, the sudden increase in contact area will lower the resistance, possibly making the weld current insufficient to allow a full size and strength weld to develop. The ac- tual timing of the forging force may be determined by measuring the weld force and current as a function of time. 4.3.3.3 Weld Time. Short weld times are desirable When welding aluminum because of its high thermal con- ductivity. Thicker sheets require more weld time than thinner sheets, Since short weld times are desired, the rate of heat rise should be steep. However, excessively high rates of heat rise will result in porous, cracked welds, ‘or Weld expulsion. 43.3.4 Weld Current. Higher currents are gener- ally required for welding aluminum than steel and someAWS ©1.18/01.1:2000 8 uso ez (so) cz (sore 1 oor fomesr (oor ox | «mer dos | yoy wed | pian, Elranmmamesa| a EF coum | Ca smupeyy 0001 say vearddy oun pag, S198 “a, one esniawe DB ,adeyg pur smpleigy apoio, SouluoeW adh jonu09 edols D-y aseyd-2I6uIS Uo sfolry winumLNIY 10} sisjoureseg BuIpIEM 1odg 20 Cane no aayAWS Cr.tMC1.1:2000, Table 18 Spot Welding Parameters for Aluminum Alloys on Three-Phase Rectifier Type Equipment ko Amps Cycles? see a = mmm Gin) { —mméiny | amet Weta Fone | wes | ee | wea Heat “041 (0016) | 139 063 7630) | 20¢450) 441980) | 190 | None 1 | None 1.02 (0.040) | 15.9 (0.63) 76 (3.0) 3.2.(730) 8.0 (1800) | 320 None 3 1. Blectode material: RWMA Clas 1, 3 Tis top and batom elecvodes should hae the seme tip radia, or one 3. Bh free and cure values for alloys ue 2014 FP 4 apoce 5052 and 6061 4. AC 60H equipment other metals because ofits higher electrical and thermal Conductivities and low surface electrical resistance after cleaning. Current sloping is frequently used on alumi. ‘num to control the cooling rate to reduce weld defects 44 Stainless Steels, Cobalt-Base Alloys Nickel, Nickel-Base Alloys, and 4.4.1 Introduction. Mi ‘eadily resistance welded. niekel-base alloys with that are normally diffi cracking. ‘An interesting phenomenon known as coring has been observed in the heat-affected zone of resistance welds of nickel-base alloys. The area may appear to resemble a crack depending on the etching procedure and magnifica, tion, However, when iis property etched and at enough ‘magnification, the area can be seen completely filled with dendritic materiales shown in Figure 2. Based on its dem dite structure, the area sppears caused by either incip ent melting or a crack which has been back-filled by the molten Weld metal. Coring can be reduced in some welds by external water cooling during welding lost of these metals can be The east preciptation-hardenable Tow ductility are among those ult t0 resistance weld without has ras tip and he thea lat cp >. 4, and 7075-76. Somewhat lower valves may be used fr alloys such an Many of the alloys discussed inthis section are precipita \ion-hardenable, For these alloys, a postweld heat treat ment is usually needed to produce a hardness in the weld region similar to that of the alloy in the fully heat-treated condition, wesapers a eee Figure 2—Coring in Nickel Alloy 718 (UNS NO7718) Resistance ‘Seam Weld, 200X ,AWS C1.1MIC1.1:2000 Table 19 Spot Welding Parameters for Aluminum Alloys on Three-Phase Frequency Converter Type Equipment (Single Impulse Welds) Electrode Diameter and Shape? RADIUS Weld Current | Wetding Time oa Net Electrode Force Approx.) Cycles ah XN a) amps 1000 | (60 persee) Sheet Thickness Radius Post Post ‘mm (in) mmény | weld Forge | Weld | Heat | weld | Heat 83100) | comm | 159006 |” 7640) | 2250 | 22600 | a6 None | 172 | None MILE | 790030 | 2541100) | 2700 | S3tr20] jo | Nee | 2 oe @ms) | comm: | is9@6) | 76a | 22.500 | ssa2m) a | gs 1 3 me} 79030 | 2s6a00 | 27060) | rine | a | 8] f 2 881003) | comm’ | 1591063) | 10240 | 27.600) | sss] 36 | 90 1 4 me f 9sc3n | asso | 3.170 | soso | 39 | 39]! 2 120010) | comm | 159006) | ore | 3.1400) | 62050 | a2 ne | 4 4 MILE] 953 | aseciom | 36t60 | soo | 4 | BS | 2 4 Trans) | coum | is9.06) | sro | s660 | sous | a6 | 139 1 5 Mie | toa | aseaom | 400) | 220 | 3 | BS] t 4 1600065) | comm’ | 1590065) | 15260) | 400m] 89.2001 sa 139 | 2 5 Mme | 12.7030 | 24000 | s8c1300)| 133290 | 9 | 3 | 2 6 HOON) | coms | i596 | 13260) | s3c200)| 1110500] 6 | ara 2 6 mie | 159069 | 258000 | 71 1600)] 1eoGe0 | $7 | sad | 2 6 Peoow) | comm! | 222087 | 132160 | 62a] 2see0] @ | vag 3 6 MIL | 159063) | 254100) | socis00)| ie2ceom | & | 28 | 3 8 2281009) | comm | z22(08) | 152160 | 114600 142019} 75 | 300 3 8 Mi} 159(065) | 256000) | 107240] 23605310] 3 | eo] 3 8 2540100) | commit | 2221087) | 20060 | s9200| 1.8600] 8 | 240 3 8 Mae) 22087 | 2s¢a0m | 125¢810| s02(670| $1 | 39 | 3 10 2180125) | comma: | 222¢087 | 20380) | 200.4800) 22.24 060) | 109 40} « | wo Mit | 22087 | 25400 | 1784000} 44310000] 10 | Bo | 10 General Notes 1 COMM = commercial requires, 2. MIL = miliary requiem, 5, Blestode material: RWMA Class 2 chs severe wosne4.4.2 Surface Condition. The surfaces to be welded should be clean, and free of contaminants that can cause inconsistent welds. In addition, some contaminants might contain a low-melting-point element such as sulfur or lead that can cause hot-cracking in the welds. Machined surfaces and mill descaled rolled-sheet surfaces may be welded after solvent or vapor degreasing. Some solvents are toxic and breathing the fumes ean cause dizziness. Other solvents are flammable and require good ventila. tion; therefore, proper precautions should be taken, 44.3 Weld Parameters. The data shown in Tables 20 through 37 are offered as a guide to develop welding Schedules for stainless stels, nickel, nickel-base and cobalt. base alloys. The following sections are comments and discussions pertaining to these tables. Additional com- ‘ments and discussions applicable to the above metals arc resented separately in 4.7 443.1 Electrodes. Most of these metals retain their high strength at elevated temperatures. Therefore, clectrodes for resistance welding these metals are usually RWMA Group A, Class 2 or 3 copper alloy (see Table 8), ‘These copper alloys are age-hardenable and thus have igher strength than RWMA Group A, Class 1, which are not heat treatable, 44.3.2 Net Electrode Force. A higher electrode force is needed for most of these metals as compared ‘with earbon steels, 4.4.3.3 Dissimilar Alloys. When dissimilar alloys of similar thicknesses are welded, penetration of the weld nugget into one alloy may be less than into the other alloy because of differences in melting points and thermal and electrical conductivities. For example, when ‘Type 321 stainless steel is welded to nickel alloy 718, penetration into the stainless steel will be less than that into the nickel alloy 718. Penetration into the stainless steel can be increased by installing an electrode with ei. ther @ lower thermal conductivity or smaller face area, or both, on the stainless steel side. The lower thermal con. ductivity or smaller face decreases the heat conducted ‘way from the stainless steel by the electrode. A smaller face area will also concentrate the weld current of heat into a smaller area. 45 Copper and Copper Alloys. Copper and copper ul- loys can be resistance spot welded although copper and some of the copper alloys have very high electrical and thermal conductivities. Electrical and thermal conductiv- ities are among the properties of a metal that can signi cantly affect its resistance weldability. The data shown in ‘Table 38 may be used as a guide to develop spot welding schedules for various copper alloys, The following tec niques may be used to facilitate resistance spot welding of these metals: AWS C1.1MiC1.1:2000 (2) Plate the faying surfaces with a higher electrical resistance metal (c.g., tin or nickel), to compensate for the low electrical resistance of the base metal. This tech- nique can greatly improve the resistance weldability of copper. However, since the plating will alter the chemical composition of the weld, its acceptability should be eval- uated based on the service requirements of the welded Joint, (2) Use electrodes faced with a refractory metal like {tungsten of molybdenum (eg, RWMA Group B, Classes 13 and 14), to reduce alloying and sticking of the elec- trodes to the workpiece. ) Use a short weld time to minimize metal expul- sion and sticking of the electrode tothe workpiece. (4) Because of the narrow plastic range of copper and copper alloys, use machines with a low-inertia welding head. This provides faster follow-up to maintain pressure ‘on the joint to prevent metal expulsion. 4.6 Titantum and Titanium Alleys. Titanium and its al- loys can be readily resistance welded. Although they are highly sensitive to embrittlement caused by reaction with air at fusion-welding temperatures, inert-gas shielding is ‘not required because the surrounding base metal protects the molten weld metal from air contamination, Before welding, the surfaces should be clean. Foreign Substances can adversely affect the weld consistency, In ‘addition, some can contaminate the welds with such in. {crstitial elements as hydrogen, carbon and oxygen, Increases in the concentration of these elements can sig nificantly decrease the weld ductility and toughness, Seale-free surfaces may be welded after degreasing or after degreasing plus pickling. Pickling may be carried ut in « water solution containing 2 to 5 percent hydrof- Imorie acid and 30 to 40 percent nitric acid by volume. Pickling acid, hydrofluoric acid and nitric acid are haz. ardous to the skin and eyes. Hazardous fames can be pro- duced by these acids and violent chemical reactions can result when acids are mixed with other chemicals, espe- “2 a U (Cxouddy) wus 92 re) uauin3 Buon ay Cy deus pur sayptingg 9p0239913 1S1901S Sse]UeIS 10} s1qaWeIeg BUIDIEM qods uopesing sores, nah ew coos sus ont thAWS C1.1M/C1.1:2000 Table 22 Seam Welding Parameters for Stainless Steels’ ectade Width Minima a Shape! Comacing é of Tine Or 76mm for sam Gn Gi) Maximom | Maximum pe w RADIUS] — Net Speed | Well” | weiss | wetding | “LEE Sheet Electrode | On | (Pressure- | Speed | per | Caner & Thickness w Fore © | tine | ‘Tight, | mimin | Maer | capmony |S mm (in) mm (in.) KN (Ib) | Cyclest | Cycles* | (in.fmin) (in) Amps aa aso] 4819) | 13sc00 | 2 P13 | sio@o | eto | 6a am e200) | stim | tseasy | 3 1 | 1306 | asous | eto | esos ee ee Goer) — savas | 200s | 3 | 2 | Iau | seouy | $e99 | $4029 Secon.) S402) | 2aacon | 3 | 3 | 13th | eons | 2590 | 29030 garemo} — savory | 67600] 3 | 2 | 130 | seottg | 20 | 72030 Seewonis)) soz | aes || 2 | rats | soci | $m | 7200 assomn} — g4o2y | sucoy | 3 | 2 | 1463 | Sou | TBO | 29090 asso) —9sosy | sre@sn | 3 | 3 | 138m | sootias | $282 | 33027 gygoon) — asap | kaso) 3 | 3 | 13D | soot | ieew [ILO imam! ssmsy | smamo) 3 | 4 | Ioan | amen | ee | Nims Lies} 2750 | nice) 4s | | rity | Geom | tase | 1250s s3rio0e | 27050 | szisso| 4 | 5 | Leo) | asotiny | 13200 | 15840e Litoom)) —ssoasy | ssecaisy| 4 | 5 | tas) | dows” | 1500 | 12 1estoors,| 1391065 fromaro! 4 | § | tofany | aol) | 12200 | tsas poems] sams (nsiasn| 3 | § | asas | fare | ieee | 250s arou| oer — Yasar] | | Sota | aunty | role | 120/075) sso} wor |wsscmp] 6 | 6 | toc | dm | edd | 205/080 GepcaNoe 1 Tops of sao, 02303 308 3838, 310 316 37,321,347 a 40, 2 Blswove atl RVDHA Cas 3 5. Forage stents mtu coing rep net hob nce 30 pet 4 ACOH equipment, 4.7 Welding Data Comments and Discussions Appli- ‘cable to Various Metals. The following comments and discussions are applicable to the spot and seam welding data for all ofthe following: (1) Uncoated carbon and HS steels (2) Coated carbon and HS steels (3) Aluminum alloys (A) Stainless stets, nickel, nickel-base alloys, and cobalt- base alloys (5) Copper and copper alloys (6) Titanium and titanium alloys 4.7.1 Spot Welding Electrode Face Diameter. The electrode face diameter affects the electrode pressure and current density experienced by the weld nugget being formed. Face diameters greater than those recommended in the tables will reduce current density and electrode 26 pressure, Similar results occur when the electrode face ‘diameter increases in size during welding due to wear and deformation. Electrode face diameters smaller than those recommended may result in expulsion, excessive indentation or electrode sticking. Electrode face diame- ters other than those presented in the tables may be used. However, the welding schedule must be adjusted accord. ingly (see Figure 1 and Table 40). Care should be exercised to prevent excessive increase oF decrease in the face diameter during electrode dress- ing. Where a flat-face electrode is used, the face diameter should not exceed the value given in order to control the electrode contact area, 4.7.2 Electrode Face Width (Seam Welding). Elec- trode wheels are used in seam welding. Therefore, elec- trode face width, rather than electrode face diameter, is specified in seam welding.AWs.c1 ‘wor, 4:2000 Table 23 Spot Welding Parameters for Annealed Nickel-Copper Alloy on Single-Phase Equipment esind Dianeer ‘Shae — Ga Mina Fabs conacing : orca a Th mt — itp | Minin | rons we vitae | RET | MI" | Rat stiinam Sheet d D Electrode | Weld | Current - Spacing ‘Shear race | mm [agin | TR | Tine | ae | SS, | Page [Ses | Shae tamtn) | “wae” | “aie? | asta | cys | ORE aint |) 013 005) 8130003)| 40,016)| 01016)| 094220] 2 | so00 | 641029] 4,025) 25.010) oan 925.0010) | gam | G4loas| $5{G3R] 39072 96s aan assromzn] socois)| so%nim| 12a] 3 | shoo | aigan| 7aeap| 39012) assy 938 com] 4o@t6)| 40019] 133000] | Senn | alta] 731029) 3301] a6 07m 10 (0063| 400016)| 79%030) 13360] 4 | S300 | gaan | Joad| 3301] Basa 2icia0ss)| 400016) | 601080 | 1asca0| | Sapo | E4028 | 29/038] 3201] ess con 318125 400010) 1600085)| La5Ga0) 4 | Sonn | alga | 27:03] 360010 992.210 038 0013 93810015}| 48.019| 48,019] 13300] 2 | sem | 62020] 2930] 331] 111050 gssiouai)| 480015)| $80019)| 133000] 6 | S500 | Eatoan| 931038] 32019] Lat asm oMsia0s| 450015)/ 80010) 14330] § | S300 | Eatorm| asian] $3013] 12 gam 100%} 480015)| 60080] 14330] | S400 | alos | ni@an| 2e0I| '22e@ Ze 0099 | 44019} /t601069| 48.339] § | damm | Galas liesiede | 36.019] TsecI0 3i8(0125| 48(019}/re00069| 13a] & | 93m | Ex Oaslerese | 36.010 139.60 osioIni 9s3a02H) 45:015)| 43.019) 133G001 12 | 6200 | 29.03/11 040] 33¢01| 200030 938.0090] 481015)| 8t015)| tasasn) 12 | gato | 29,058 | Et GA? | 33.013 | 20ncsn heaeeos] 4aca19] t80019) 1433] 12 | S300 | 79003] 909m] aeiGld| ZS 23640093 481019) e0(065| L383] 12 | 7am | Istosn| ses | Bete | 22200 Hi @125| 48019} 1600088 | 15690] 12 | ga | sslorh| Laseso | 3801 | 23630 orsraah 27810085] 48.019) s80019| 11490) 12 | 10300 | 95003| 160051 43.01] a7689 a 0008)| 480015)| 64'025| 334(755/ t2 | it3m0 |i2siGan | See] 4zeIn| 276; 23600055] 486019] oto) | Aascan| tz | tam |i27inan | males | sec | 4e810, Jis@229| 40019} i6ot0e | 345000) 12 | aw | 29,0ap| aes | AE OI| $4aimID 140096 1290006] 29030] »9¢30 1201 a7} 12 | 13300 | i60.08»| 286«113)| 19030] sis) P3e000%3}] 791031 | 80089 ian arm) 2 | ISam | eolocn | seein | 73,032 | 480m 3.18 (0.125) | 7.9 (0.31) | 16.0 (0.63) [12.01 (2700) 12 16200 | 16.0 (0.63) | 31.8 (1.25) (0.32) } 10.50 (2360) 236008) 23600085] 95.039] ss103anfz26.ano) 20 | 2240 | 90.075) 180.25 94030 [1726 08) A825 95030] 95 t03n [228 ara 30 | domo | n0(o7| seas | 94932 [1236.08 a8 025) 31800125 | 1270030 | 12.0030 p24 500} 20 | s0000 {222089 Ja1a1ss | 119:04n smn ces0 Sens "Ete heme be trae dane wih ee hr ret nl mano il ier gerd tn nt ble 2. Bletrde material: RWMA Class 1 o Cas 2. 5. Nominal chemical conposiian of nicke-copper alloy (UNS NO4400), wt Fe: 66.0 Ni, 315 Cu, 1.35 Fe, 0.90 Ma, 018 Si Fearne eta has 2 0126, 00058,AWS C1 3wC1.1:2000, '$S000 9 c1.0°% $'0-u¥v 06024 661 "99 51 ¥N 099 3-24 OOFEON SN A ado: ‘su oJ uns sr uo yea ox gs of Spina apy Sep ae roy J0 won sods ropes bo ¢ pm 2-9} 0 peg BUN HAE 50D VIA eu pane SN Fa, 9 r ot oro P 1 6 z t ol z I 5 SCO) #9 z 1 5 Geoys z 1 9 Gros (os) 21 sayng | 9pm | sat on wW oo) |} wap Cup] smpey | cup uta P a wosua, | cuyum | pram una, | sopweg | unui, (95 104 09) 045 22H 9K Pa i un vedrys pu stoureig aponsop SeuyoeHl Jolenuog Aauanbo1y eseyd-oe1u uo -Aojy Jeddog-19x9IN pe|ZauUly 40) sisjoulezeg BuIplam Jods ve aren 8 i 38 i i uiAWS C1 1MIC1.1:2000, Tat Seam Welding Parameters for ible 25 Fr Annealed Nickel-Copper Alloy! on Single-Phase Equipment lecrede Whee! Width ee Shope? jw AL) pp mous sina oo Contacting = Overiap i Net Of Time mam (in.) sa weid | weiss | weiaing | LEE Sheet w E Brccuoue | On |¢Pressure) Speed | per’ | Current | gE Teka | made? | mae? | Beds, | face | ime |e | smn | nce [pre | SI, smm(iny | “Min | “Max._| mméin)| avy | Cycles | Cyetes | cnvminy | "aye | AP 0280010)/ 9503n| 4010] 760] 8900) 1 | 3 | iwasqH| aman] sao | esaa 938 0015)| 9503 | 400019) 152160) 133000] 1 | 3 |isos(ay| aman | apo | S232 933 0021) 95 037)| 48019 | 152(60)] 222500] 2 | 6 | 'sestam| araun | oso | 23°03) Be4co15)| 9.5(037)/481018)] 52(50)] 2671600] 3 | 12 | soso arcin| 300 | 79.03) 979 0031) 951037) | 480.19 | 1520601] 3:1(700)] & | 12 | assui9)| a2 | 100m | e032 137,006 [127 (050)] 950037 | 152160) ]11.1@300)/ 8 | 12 | Sostam| 3500) | Isao [renaen Genera Notes 4; Nominal chemiea composition of nike-coppe alloy (UNS NO4400), wi: 66.0 Ni, 31.5 Cu, 1.38 Fe, 0.90 Mn, 015 Si 0.12 C. 0005 5. 2 Bleeuode material: RWMA Class (Pefenea) or Cas 4.7.3 Blectrode Face Shape. The electrode face shape influences the weld size, shape and surface inden- tation. To maintain consistent weld quality, the elec trodes may requite redressing after a limited number of ‘Welds to maintain their geometric shape and proper face area, and to minimize contact resistance between the work and electrode For special combinations, such as unequal thick- nesses, itis often desirable to use a combination of elec- trode shapes or contours to produce acceptable welds. Generally, a smaller radius contour, which produces ‘greater concentration of weld heat, will produce higher Weld penetration in the sheet contacting it. Conversely, a larger radius contour, which produces less concentration of heat, wil produce lower weld penetration in the sheet contacting i. Standard RWMA nose or tip geometries of spot weld- ing electrodes are shown in Figure 1. 4.7.4 Electrode Cooling. Spot and projection welding electrodes should be internally water cooled to prevent overheating which results in electrode sticking and de- creased clectrode life. Intemal coolant flow rate require- ‘ments may vary from 1.9 t0 5:7 Limin (05 to 1.5 gal/min) per electrode, depending on the type of welding system. ‘Water coolant temperature should be less than 35°C (95°F), For adequate cooting, a maximum electrode face thickness (nose thickness) of 13 mm (0.50 in.) with a properly positioned coolant inlet tube is recommended. ‘The coolant inlet tube should be cut on an angle at the tip ‘and inserted to contact the bottom of the water hole in the clectrode to ensure maximum cooling of the face. Ifthe coolant inlet tube is not properly placed, steam or turbu- lence may develop within the electrode tip, reducing heat lissipation. The reduced cooling of the electrode will de- crease the electrode life, External water cooling may be used in combination with internal water cooling to provide more effective cooling ofthe spot welding electrodes. Jn seam or roll-spot welding, the wheel electrode should be cooled with an external water stream directed at the weld area, cooling both the electrode and work~ piece, where practical, 4.7.5 Net Electrode Force. Correct weld forces, for a aiven combination of current level and weld time, are re- uired to produce welds of optimum nugget size and penetration without expulsion, porosity, cracking, or ex- cessive indentation. Excessively low forces do not pro- vide current uniformity and molten metal containment, ‘and may result in expulsion at the joint or electrode-to- workpiece interface. Excessively high forces produce 2AWS ©1.1M/C1.1:2000, doo vonsod ea yoru og =Upeu 3a wo part an a S009 C108 STOW AH SCI nO 1 N99 4-6 COOHHON "ArBupioae patsipe 2 prs ou 09 pa ea eto pony 1s (06 | 4010.16 |ie0106H) tasaa| 6 | sen | eaoan| ssn] 2B] Re 24 08)| éo16|I601065| asc] § | Sam | E4loan| S2an| ZEO1 | oeoaaD 32,025)| so(16)/ie0108) 145020] § | Sam | soa] sslesn| Sh019 | 24am 028 0b 925(0010 | 400016)| 48019] 1422] 4 | 290 | e429] 65025] s0@1m| arears 99800015)| 400016)| 48015) Laatean| 2 | gam | 21038] 64029) 3901 | a7 ars, 95300021) 4o.016)| 43019) Leagan & | sim | 6499] $4103] 3301 | 996a2 079008 | 400016) | 48019] Leas] & | sam | caean| T1lC3] 33019 | 99s cz Xs (6) | 4040.16)| Seto] aso] ¢ | 3500 | Sata] 75028] 32012 | Las 24 08)| 40016 /i6008)] tro] & | sam | caean| <203p] 32018) Lanai 22 (05) | 400016) [t6006| recon] ¢ | sau | aGan] ss03n] 38019) 13s csp 038 0013 « 9380015] 4219] 48019] 16006] 6 | 140 | 64029] s4o25! 3001) | 131 a0 O5300021)| ¢80015)| 48019) LeoGen| § | ean | 62003] $4029) 3001) 121 aap 299 (0081)| 48(019)| 481019) Lose] $ | sam | c2ean] £41022] 300% | 129230 1s 1096) 480039)] 79:03] tran | § | Som | GalGan] 2828) 3301 | iss a7) 24 (00%) | 48018) |i60008] recon] 10 | samo | Caan] EAG3] 2012] Lean 22 (0128) | 4810:18)|1600085| Irecoo| 12 | sao | eegan| sgGan| 41@19] Baer ossiolnhin 9330020 | 480019)| 40016] 124000] 12 | 4000 | 790039|111048)| 301 | 2400 SM (OMD | 481015)] 48019) 13608] 2 | dio | FOILS] Biel 22s 16 (G06) | 48001] ¢80015)| L7s aD] 2 | 33m | toGan |p Gey] 391012 | 29895) 24 (005 | 481019)/ 601065] 220.00] 12 | 3900 | ralbanlianan| SEI | 2386580 32 (0125) 480018) |1600085| 245053] 12 | 6300 | 79035 | laren | eID | 258167 ons ssne 97082 | <201%)| 48@19] 211.00 2 | 6700 | 95(03|1430056)| <6 | aor 1s (04s) | 430019) / 7903n| S11Gm| 12 | S100 | 333n tea ss| SE.0r8 | 390.020 24 (00 | $81019)| 850039] aungan| 12 | aso | 93fon [99S | S6U2R | 230050 32 (0125 | 481019) 0106] 334090] 12 | S900 | Satosn [woes | S103 | 874290 Le oles 1s 606) 481019] 79.039] 9210070] 12 | 1200 | e006 | 2¢611.| 290030 |r e750) 24 (00m)| 791031 [i600 |i090 00) 16 | 2m [levees |a0euIn| FIeSp [Bee 320125] 43.030 [i800 tnsr acon] 20 | 1am |teaiesn | seadtse| 22.030 | 1233 750 2 (0093) 24°G09| 95.03| 93.039|1221 2870] 20 | 100 |190«75| 302(119)| 940037 {957 aso 92 (0125 | 1111080 [111 (ha lane 00] 30 | 20000 | IDOI | aS | es Ga |sRST eo 320% 32/0125 | nea {114104 [rs44¢s210] 30 | 20100 [2228 [223039] 1.1 om [mar son Serna 1 Electrode shape may beat rather than domed in wich 2 Electrode material: RWMA Class 2, Class 3, of Class 3. Nominal chemieal comp ‘007 s. 4. Inictes molyodenumsipped electrode Fae tn ‘test nanig hasan 31 eth shear suengts and mpg diameters wil be higher and large than shown in the tbe. position of ncke-chromium alloy 600 (UNS 06600), wi: 76. Ni, 15.8 Cr, 7.20 Fe, 104 C, 0.20 Mr 0.10 Cu, 0.04 C.' 4000 "'8 06009 FOOD sOO"YH UL IY OF ORD SHO "UL UFZ"=H SU9 49 FSI YNOEL 1H {OSLLON SNMD OSX Ao wOAY>4=yoIU Jo LoEAOS | 181990 7559 VICAR ‘AWS ©1.1MiC1.1:2000, (oot) s¥'s [(ox2) 1021 sro vesi| Grove oseot | ot oer 0056 | 8 Gro oe ose | 9 28 z ore | or eo st scorer i gore | 2 | corer (4.0081) | apres sdaty | sais | (an NX (ca) | uy] Ca wae Dooce | sy ¢xouddy) | ouny | aas0y, smpey | (uy wu | ssouyonuy, snoH wan | prow | sponse. a 94S poy Supra, BN soiourmicy | unui Can Na e8i0N wiSuang 7245) caste osu, muy oma neu S sniove oe deus pu saute apanarg quauldinby aseyd-e/6uls uo -0S2X AojIy winlwWO14D-[e49IN PleouUY 40) Sio}aWELe BuIpIey ods ez age 32 tame ia ty, erase nau pend Pea en‘AWS C1.1N101.1:2000 $$ L000°'6 010'0'9 5009 S00 "WH LO IV OF0-N9 S30, "su ooo jo wnat wore coo 1 Hi a & oo tt 1 8 oo 8 { £ o8 9 t 6 (seo v 008 \ 8 Goss sduy =a | sm sn (xouddy) 903) oH (Cut) wu Aung, ° wots, | (up ane Su winaiyy | Soouie (aos 9) 191 PScure a HL ion, oth sniava ade pu sour aponoora SouluoeW JeHeAUoD Aauenbary eselq-22141 UO -0S2x AoNIY WNIWIOI4D-[ax9IN PEreoULLy 40) s18JeUIeLeg Bulpjom 10dg 6z 1081 33‘AWS €1.1101.1:2000 ' 4000'S 0£0°0'9 H10°RD S00" OL IY OF0"AD SHO OF Z"A4 SLB "DESI NOEL 1-1 (OSECON SNA OSLX jt wmOIID1O4H Jo BONNOAwOD fONLDYD YON "ESM © 2 eID VINA euDIe apOH “| wwe | soourig | wnuntiyg 13MN, Cxeuddy) aun Supi9N8 untae ‘20404 9p0n991g 7N fof son jadays pue spjaieig, 2panseia, SHON 1339 O01 (ear0) acy oe 96 8 oe ee LORIE ss 6010) 9€°2 se (eo) zzz | (2000) is'1 e (Coos) 972 (€9.0) 651 | Zeo0) 180 se | 6] Canna | an Nx ayy] Cus une su, | our | alo PPA ay uur | ssouxorgy Pras | Aetaq a e2us, Cup aw | prom stiog SOUIYDEW JeyNIeY YSIG Aug aseyd-ees41 UO -0G2X AO|IY WNIWIOIYD-|¥9IN Po|eouUy 10} si@JeWIeLeY BuIpjam ods. og 1421 Siete ommnny moto Rovsedor swearsAWS C1.1MC1.1:2000 Table 31 ‘Seam Welding Parameters for Annealed Nickel-Chromium Alloy X750° on Single-Phase Equipment Electrode Whee! Width nd Shape! w Minimum RADIUS Contsting ‘Overlap o sam (in) N oTime | Weld Welding | PLT et rime | We cling Sheet |W E tecrose | On| Pressure | Speed | Welds per| Curent | ht ‘Thickness | mm tin) | mm Gn) Force | Tine | Tigh) | mmnimin | Meter | Approx] SEL, mm(in) | "Min | " Max KN Ab) | Cyetes | Cycles | inémin) | Gn) | Amps 0250010] 64025)]320013] 76@0| 1.8400 | 1 3 [acs [79000 | 3600 [asin 038(0.015)] 6.4(025)|32(0.13)| 760] 3:10) | 2 4 | s10G6 | san | 3500 | 64025, 053 0021] 9'5(037)| 56(022)| 760 | 62400) | 3 6 | 760;30)| 55004 | 8000 | 29031 0:79,003)] 95(037)| 48(0.19)| 76.0) |102.2300)] 4 8 | 760G0)| 700m | 8500 | 95.037, 1.37 0.062)| 12.7 0.50)] 48 (0.19) | 152(60) [1784000] 8 | 16 | 300,12) | 390(10) | 10300 | 9300.37) (Grae Nate 1. Blecrode mata: RWMA Class 2 of Class 3 2. Class 2 preferred for 0.54, 0.38, and 053 mm (0010, 1015, and 0.021 in} thicknesses; for 0.79 and 1.57 mm (01031 and 0.062 in) thicknesses, Clas 2 3 i ia 3, Nominal chemical composition of nickel-chromium alloy X750 (UNS NOTTS), ws: 72.0 Ni, 15 Cx, 6:75 Fe, 2507, 085 Cb, 080 AL, 0.70, Mr, 005 Cu, D4 C, 0030 Si, 0007S, metal indentation, distortion, and a small weld nugget di ameter. As the electrode force increases, the resistance values of the workpiece circuit will decrease. Lower re- sistance values require higher current levels in order 10 provide proper heating of the faying interface to ereate a proper weld nugget. Therefore, a correct balance of cur- tent, Weld time, and electrode force is necessary. Elec- trode alignment is necessary for proper weld force application. Nonparallel electrode faces can result in a limited clectrode tip contact area which will experience a lange effective weld pressure. The non-uniform applica- tion of weld force may result in excessive surface inden- tation, localized overheating, expulsion, or undersized weld nuggets. Non-vertically aligned electrodes may produce similar results, Further, electrode wear may alter the effective electrode pressure if the electrode face area increases or decreases. ‘When a forging force is employed to prevent weld nugget cracking in resistance seam welding, an inter- iittent drive is used so that the forging force is applied directly over the intended weld nugget. When an inter- mittent drive is used, the electrode wheels are stopped for each weld nugget acorn 4.7.6 Weld Schedule Times. Properly set times eon- tribute to high quality resistance welding. The values shown forall times are in eycles based on 60 cycles per second. Some of the time variables discussed below are usually part of the welding schedules, but are not neces- sarily shown in the tables. 4.7.6.1 Squeeze Time. This time includes allow- ‘ances for delays in valve shifting, mechanical movement of the weld head to the work, the complete pressurization of the cylinder, and the bringing of the pieces to be welded into intimate contact. Inadequate squeeze time results in inconsistent weld quality, 4.7.6.2 Weld Time. Proper weld times are based upon current and electrode force values chosen for the materials being joined. Longer or shorter weld times may result in inconsistent weld quality 4.7.6.3 Hold ‘Time. The electrode provides a con- ued force to the weld nugget, and cools the workpiece as long as pressure is maintained. The number of cycles of hold time needed varies with material and thickness. ‘Actual hold time is usually several cycles longer than the specified hold time because of mechanical delays. 35AWS C1.AMIC1.1:2000 '$ 4000'S 0£090°9 700""0 Sov "¥HL AL ‘TY ORO 8D $3.0“. OS'2"s *(upuooe “Spm 2a 1 2 Ras Sat "18 “OSLLON SNED OEE Kr wnnuosy42oq4 J Loon oD TeUON 909 pu oa ‘wnuuyy snicves mo] jd04s pue pias spate, 51 z] a se fo |e] oo sofa} a} =]a]-]s = ele o Goer -|-|- [1 ae =| Soy won| $9404 | sepoa> | soning | se1o¥ | so1aK— ay xoxddy) wo | suey 8) Suh uit | ou, Sono, SS Pong so10W | afte, ro0d) | prea ays uy ara | Sanpayy ‘wpa wanrunonuy dian, awa ‘SOUIYoRN 19V1eAUOD AaUeNbeL4 eseyd-2O141 UO ,OSZX Ao||y WNIWOYD-IO49IN pa[eouUy 404 sisjeuieiey BuIpjem wees ze age‘AWS C1.1101.1 :2000 Te 9p us? irae pose euayeassauyoyfebunBupfom vay Avsso900 34 ene td on mio oat vou na par ap awe fo sa peaes Hace posse ee aa "ESS 0. SHH) VINA EUAIEN apa T sno 555) oe | or ool iz | 98 a | @ a | L fos (coos) ss e | se (Oost) 2002 ofa (cove) 9p 2t onc 9s. ose (cup an s212%9 | se1% cna | nx uy a240 uy, | 2unp shay | pra Sunomue> oven | press uM (xaidéy) it won ‘2104 aponIg HON 5 BUPA al alias son yadeys pu Wea, fbou spam SOUIUORW JouNIaY 4SIq Aig eseyd-ee14) UO ,OSZX AojIy WiN|WO14D-1849IN 40} S1eJoUIEIeY BuIp|eM JOds-/10H 37AWS .C1.1MIC1.1:2000 Table 34 Spot We ig Parameters for Annealed Nickel on etd Dinter ‘he Shape! 1 were l I ah Soe Diasec Net Welding | S525 | Minimum | ™" 6") | Minimam Sheet a D | Ekecirode | Weld | Current | Soar | Weta Shear ‘Thickness | in in, Force "| Time | Approx) | =, | spacing |STe-g] sirenste mm (in) ‘Max. Min, ‘KN (Ib) | Cycles | Amps = ‘mm (in.) a KN (Ib) 0130005 09 913,000] 40019 | 400016] caso! 3 | 7100 | 64025] 95,039] 25001 | o1sa0 935,0010)] 4910.19 | 404015) dasuon| 3 | Tamm | 2109] Paap] AGI | Bisse 938,0015)| 491019 | 401015] oso] 3 | 73m | esi025| FoQean| sl | BieGe 953/00) ] 401019 | 4040.16)| ooo] 3 | tan0 | Eaina| roan] 25.1 | G2 998 (003| £010.16 | 48(015)| oasciy| 3 | gow | eatoas| tare | saci | OES 1s (G0s3)| 01016) | 48(019)| osztia| 3 | S100 | satozs| ‘asian | 23.049 | 92200 24 (009| 4010.16 | 4815] os2aan] 3 | E150 | ealoan| igawer| eet | CSD 32 (o125)| cows | 480015)| oszciay] 3 | S200 | eatoay| ienieen| Sore | GZS 0250010 035(0010)] 48019 | 48019] os8a30| 3 | 11am | 64025) 95,039| 2001 | osoasy 93610013] 6910.16 | 48.01] aswsy| 3 | tio | Es oa) Ss(orB| RowIm | Seda? 053,00] 491016) | 48.015)] o36s0| 3 | teow | esos] ra¥orn| sean | Serle) 038 (003 | 201016 | 48(019)| d5834, 3 | faa | eafoan] 4332] 39012 | oer asm, 16 (oes | 400016) | 4¥to19)/ osztian] 3 | Io00 | Galoas| aoiean] 3212 | O71 0H 34 (0m] 40016 | 48019] Osan] 3 | t2300 | Esloa5| eouen| sors | ORS 2 @125)| 40016 | 480019)] ost] 3 | 12300 | estos] some] aon | 86% 038 05 038(0015] 4801 | 48019] 11105] 3 | 2300 | 64025) 29030] 30012 | osoasy o3s(o0an] 4810.1 | 480039] LiL a5] 3 | t23mo | &4(035] a9 an] SGI | oa 078 (00 | 4810.19 | 48.015)| 1105] 3 | treo | e025] teria | S808 | 16 (0063)| 480019) | 641025] iets] 3 | tas00 | gaio25)|iaaon| sais | L338 24 (009)| 481019) | 600063)| 16@s0] 3 | i000 | @4(023)| leawan| ase | ESN 52 o125)| 480019) |re0ce| Liecamn| 3 | 13400 | slo] eae] S312 | LSE 058008) asso0| 40019 | s0@10] 65am] 2 | 1800 | 1920) 143056) 30001 | 141020 Age(o0s) | 40019 | 40016] esam] | aan | 7903| tealaen| sea | LSP 1g dos | 40016 | $0;010| Les] ¢ | sam | F3loah|ienen| wot | LEG 24 (0085)| 491019) Jieo%aes| 19G0/ | a5 | rel0ah| saan | eaiein | bzeO 52 to1as| 4010.16 |160.083)| 149080] 4 | S000 | Z9{03H| Iwarse| 39048 | 48h ork othe 078 003 | 48019 | 480139] s00(900] 4 | 18400 | 950037] 22208| 460019 | 338.100) Te feos | 480019) | 480019)| soem] 4 | Sam | 9303p | 29098 | £5018 | Lam 24 (ompy| 48019 | 481019] Soncm] § | 13500 | ssoan{aecanl seer | BG 32 (o1zs)| 480019) | 160,085) | 4360] 6 | T4300 | Ss ta3n|zecites | $6048 | 374 @un 1610063)" {ores | e425 | 41020 re8a720] ¢ | 2140 | 50:04| 382.150)| 64,020 lrore cam 28 (Govs)| 41025 | 64002)| aorcison] —$ | Zoo |teoloen| arate] 640an [07s eaD 3 coras)| 641025 | 6(025)| sor cisoo] 10 | Zio |renioe| asus] Seon (tise CSO) 2so tn) | 19030 | 13@2n 02x00] 12 | 2540 {1901023)| 22689] 19030 |is01 exo 32 Gis] 790030 | 791035 foas eam) 2 | 200 |iso(or| sas cen| Flea [1S02 G90 HOES) [ 250039 | 9am hiseee00] 20 | s1000 {222,020 | s720225)| 951037 [ou91 econ are 1 Blectoe shape maybe flat rater than domed: a which case the shear streng table 2, Eleeuode matval: WMA Class 1 or Cas 2. 38 and avgget diameters will be higher and larger hin shown intheAWS C1.1MC1.1:2000 Table 35 ‘Spot Welding Parameters for Nickel-Iron-Chromium Alloy X" ‘Weld Time Electrodes Cycles Welding | Average | Average Sheet Face weld | Forge Curent | “Shear | ‘Tensile Thickness Diameter] tip | Force | Force Apprex.)| Sengtn | surength ‘mm (in) [Material] mm in.) [Contour] kN (ib) | KN (Qb) | Heat| Cool|Impulses| Amps | KN«b) | KNB) 0.76 (0.030) RWMA]6.4(0.25)] Fiat | 4.0(900) 11.1 2509] 8 | 2 | 2 | 18900 | 61301380) 3.88 (872) Chass 3 1,60 0.063)] RWMA|7.9(031)| Flat {11.1 2500)]17.8 4000] 10 | 2 | 10 | 21-700 |14.62,3290)) 8.68 11950) Chase 2.39 (0.094) RWMA|9.5 (0.37)| Flat |19.6,4400)/33.4(7500)| 9 | 2 | 4 | s0sa0 |21.42,a800)| 18.99 (4270) Class 2 General Nae 1, Nomina chemical composition of nicks ron-ehromium alley X (UNS NOSOO2), wt‘ 47.5 Ni 21.7 Ck 185 Fe, 80 Mo, 1.5 Co, 0.1 Table 36 ‘Seam Welding Parameters for Nickel-Iron-Chromium Alloy X2 Electrode | Net Electrode Force Weld Time Wheel Face KN (kD) Welding | Welding Sheet | Width! Corrent | Speed ‘Thickness | (Flat Face) Heat} Cool Forge | (Approx) | Welds mmfin) | mmGn) | Weld Forge | Cycles | Cycles | imputses | Cycles | Amps | perm (in) 0,76 (0030) | 4800.19) | 667(150)| — None 10 2 1 | None | 20250 | soca 1.60 (0.063) | 79(0.31) | 8902.00) | 17:79(4.0)| 10 2 8 15 | 21500 | 39410) 239 (0.094) | 9.5037) | 20.24.50) | 2002150) | _10 2 4 25 | 33000 | 3150) Gener Notes 1 lecrode materia: RWMA Css. 2. Nominal chemical compotion of nickel iron-chromium alloy X (UNS NO6OQQ), wt ¥: 47.5 Ni 21.7 Cx. 18 Fe, 8.0 Mo, 15.Co, 041 C. Table 37 Spot Welding Parameters for Cobalt-Chromium-Nickel Alloy? Electrode! Force Weld Time Welding | Average | Average Sheet kN ab) Current | “Sheer | Tensile Thickness | Diameter | Tip Heat | Coot Forge | (Approx. | Strength | Strength mm (in) | mm in | Contour | Weld | Farge | Cycies | Cycles | Impulses | Cycles | Amps | kPa (ks) | KPa Gi) 0.76 48 [rim | 334] 72] 1 | os | 1 45 | i360 [ sos] 565 (0.020) | (19) (730) | (1600) (129) | x2) 1.60 79 | mim | 890} 1780] 1 | 25 | 4 50 | 1500 | 2758 | 2068 008) | 31) (2000) | (4000) 4.000) | 3.00) 239 | 127 | wa | 1334] 3781] 20 | os | 8 | 200 | 19800 | ssn | aost (054 | «50 3000) | (8500) (8.080) | (5:73) General Notes 1. Bled material: RWMA Clase 3 2. Nominal ehemieal composition of cobalt chromium-ncke! alloy (UNS R30605), we: 52 Co,20 Cx, 15 W. 10 Ni, 1.5 Ma, 0.1 €: 39AWS C1 .1M/C1.1:2000 Table 38 Spot Welding Parameters for Various Copper Alloys Weld Time [Net Elecrode Force Welding Current Alloy Cycles KN (0b) Amps Muntz metal 4 1.78 (400), 21-000 High brass 4 1.78 (400) 21 000 Cartridge brass 4 1.78 400) 21.000 Low brass 6 1.78 (400) 21 000 Red brass 6 1-78 400) 21 000 “Manganese red brass 6 1.78 (400) 21.000 Aluminum bronze 4 1.78 (400) 21 000 Silicon brass 6 2271510) 21.000, Silicon bronze 6 1.78 (400) 21.000 Phosphor bronze 6 2.271510) 21.000 Nicke-aluminom bronze 6 1:78 1400) 21.000, Nickel-aluminum bronze 4 271510) 21000 {precipitation hardenable) General Noes 1, Sheet hickness: 091 mm (0.036 in) 2, Electrode: RWMA Class 48 rm (0.19 in) fe deter (ati), 30 depress bevel. Source: Resisance Welding Theory and Use, American Welding Society, Miami, Pid, 1956 Table 39 Spot Welding Parameters for Titanium Alloy 6%Al-4%V Net Cross- sheet | Electose | weld | Welding | Comacting | Nugger | weld Shear | Tension Thickness | Force | Time | Cament | Overlap | Diameter | Penciraion | Sieagth | Suength min) | XN) | Cycles | Amps | mmciny | mmcny | % kev) | kN by 089003] 267(60 | 7 | 5500 | 127050 | — — 7.651720) | 2.67 (600) 1-57 (0.062) | 667 1300) | 10 | 10600 | 159103) | s4@3s) | 47.3 | 22.22(5000) | 4.45 (1000) 1780070) | 7560170) | 12 | 11500 | 159(083) | — = | 2825 (6350) | 823.1850) 2.360.093) | 10.68 (2400) | 16 | 12500 | 1901075) | — = __| 3737 (8400) | 934 c2100) Genera Notes 1. Elec: RWMA Class 2, 18.9 mm (063) da. shank, 76m (3 tp as. 2 Squeee time, cycles: 60. 3. Mold ime, eyes 6 Source: “Welding an Prosess Marual—Tianiun,” Welding Engineer, Api 1967 4.7.64 Heat and Cool Times (Seam Welding). IF U.S. Customary Units: ‘a slower welding speed is necessary, the cool time should en bbe increased to maintain the same number of welds per elds per in. = ‘mim Gin), thus preventing an excessive heat input which (60° Line Frequency (cycles per second) ‘may cause undue distortion of the work. The welds per zmm are related to the welding speed, weld time, and cool time as shown by the following formula: SLunits: Welds per mm = 660 x Line Frequency (cycles per second) (Heat Time + Cool Time) x Welding Speed (mm/min) (Heat Time + Cool Time) x Welding Speed (inJmin) Where the heat and cool times are in cycles and the weld- ing speed is in mm per minute (in. per minute), 47.6.5 Off Time. This variable is generally used when the welding cycle is repetitive. 47.7 Weld Current. The values shown in the tables are approximate and are intended to help calculate and 40AWS C1.1MIC1.1:2000 Table 40 Variation of Current Density and Unit Force Due to Lack of Electrode Tip Maintenance 1 2 3 4 5 Tip Area 400% Proper Tip Area 569% ‘Tip Area 125% ‘Tip Area 300% ‘Too Small Tip Area Too Large Too Large ‘Too Large | 0.079 en? 0317 em? 0.495 en? 0.713 em? 1.267 em? (0.0123 in2) (0.0491 in2) (0.0767 in2) (0.1105 in2) (01964 in2) AtDiameter At Diameter AtDiameter AtDiameter ‘At Diameter 3.18 mm (0.125 in) 6.35 (0.250 in.) 794 (0313 in) 9.52 mm (0375in.) | 12:70 mm (0.500 in.) Unit Force Unit Foree Unit Force Unit Foree Unit Force 411 MPa (59.000 psi) | 103 MPa(15.000 psi) | 65 MPa(9 500 psiy | 45™MPa (6500 psi) | 26MPa 710 psi) Current Density Current Density Current Density Current Density (Current Density 123 690 Alem? 31.000 Alem? 19810 Alem? 13 640 Alem? 7730 Alem? (798 880 A/in#) (200000 Ain) (127 800 w/in?) (88.000 Avin2) (49.900 Alin) Result Result Result Result Result ‘There is 400% too much | Good Spot Weld Only 64% ofthe Only 44% of the Only 25% oF the force and current required force required force required force Severe indentationand | Ideal Sewp | —and current. and eurtent. and current. ‘expulsion from high | ‘current density ‘Weak Spot Weld Stick Weld No Weld At All (General Note |. Example 2 shows the cree tip siz for applicstion requting wel ing force 32 (730) anda welding curtenof 9800 A. Thus x 635 mm (0.280 in) diameter eleetrode ip will roduc w unit force of 103 MPa (1300 ps) anda caren density of 3100 Alem? (200 000 Alin’), specify the capacity of welding machines. When the electrode force has been established, the current may be increased to the point where metal expulsion occurs and then reduced to just below this point. Optimum strengths, nugget diameters, and penetration values may be obtained by this method, 4.1.1.1 Weld Schedule Options, Some welding conditions may benefit from weld schedule options. These include preheat, upslope, pulsation, postheat, downslope, and heat steppers. These options adjust the welding cur- rent before, during, and after welding. They may be used alone or in combination with one another to provide vari- us benefits such as annealing, tempering, increased tip ‘dressing intervals, longer electrode life, and reduced power consumption. 4.78 Minimum Contacting Overlap. These values in- ] 51 mm E E -—4 GEE 8 ES os & i 8 (ors) HOLE fe imme ‘SPOT WELD CENTERED i com | ay AS SHOWN T = THICKNESS J+} 51 mm (20) UP TO 43mm (0.199) fe 206 mm (80 in) ——> 204 mm (20 in) ——m | I\) ant athe ‘SPOT WELD CENTERED r 38 mm te —>} AS SHOWN (sin THICKNESS: <7 mm mf 4. mm (0.19 in) join) ‘AND OVER ® Figure 10—Cross-Tension Test Specimens 52AWS C1.1M/G1.1:2000 [101.6 mm are) ~(4.0Qn} (Osim) Figure 11—Fixture for Cross-Tension Test (for Thicknesses up to 4.8 mm [0.19 in.]) 33‘AWS C1 1MC1.1:2000 490m (0.75) BOLTS SET SCREW 22.2 mm (0.87 in) DIA. 13mm asin cS ~_— @oin) Figure 12—Fixture for Cross-Tension Test (for Thicknesses 4.8 mm [0.19 in.] and Over) 495.14 Torsion Shear Test. A torsion-shear test for evaluating spot welds may be used where @ mea- sure of strength and ductility is required. A typical set-up {or this testis shown in Figure 16, Torsional shear is ap- plied on the weld of a square test specimen by placing the specimen between two recessed plates. The upper plate is held rigid by a hinge while the lower is fastened to a rotating disk. After the specimen is placed in the square recess ofthe lower plate, the upper plate is closed over it and locked in position. Torque is applied by ‘means of a rack and pinion attached to the disk. Itis im- portant that the upper and lower sheets of the specimen be engaged separately by the two plates and the weld be centrally located with respect to the axis of rotation. ‘Three values are determined for the weld area: (1) Ultimate torque required to vwist the weld to de- struction (computed by multiplying the maximum load in newtons (pounds-force}) by the moment arm in m (in). (2) Angle of twist at ultimate torque (measured by the angle of rotation at maximum load). (3) Weld diameter (measured after the test specimen is broken). ‘The weld strength can be determined using the ult ‘ate torque and weld diameter, and the ductility by the angle of twist. Tis possible to use the test values obtained (ultimate torque, angle of twist, and weld diameter) to indicate quality. This may be done by using the standard torsional formula where 1 = moment of inertia (m* (in)) 8, = torsional shear stress (Pa [psil) M = torque (N-m fin. pound-forcel) € = distance from external fiber to central axis (m lin) ‘The torsional shear stress values obtained for the ex- ternal fibers, termed the modulus of rupture, are directly proportional to the tension shear stress. The modulus of | rupture, as determined by actual tests on low-carbon 34AWS C1.1M/01.1:2000 EDGES AS SHEARED yO Ae Lk | rn DIAMETER DRILL £—+ L—s spor weto centea AS SHOWN, | T () RADIUS" A “(Thickness w a 8 D E Fe mm fm) mm (in) mm in) mm in) (ma) (mt) mmm) Upiozs4 —Upto(o.100) 85 (1) OH)OS (ORD) BSH) «AO (OB) 2S6andover (0.4101 andover) 51 @) 512) 25) S56) 81 2)_—«A_(0.25) “For magnesium, bigh-strongth aluminum alloys and other ays that cannot tolerate these red, the radius must be increased to & ‘sullable value within the limits ofthe capably ofthe particular material. itis dasirabe to form these specimens without the necessity of heating as this wl modly the resuls Figure 13—U-Test SpecimenAWS C1 AMIC1.1:2000 “D" DIAMETER THA BREAK CORNERS. am (orang A 19mm (075 in) x 10 THREAD 22 mm (1.28 in) Two REQUIRED T (Thickness) w a 8 D E RP L co () ‘mm (in) mm (in) mm (in) mm (in) mm (n) mm (ma) _mm in) Upte254 —Upto(0%00) 25 (1) «2 (1) (05) BF (OK) 25 (1) 40 (0.16) 87 (205) 286 andover (0401 andovey St (@) _51_(2)_25__(1)_-143 (056) 81) 64 (0.25) 8 (825) ‘For magnesium, high-strength aluminum alloys and other alloys that eannot tolerate these radi, the radlus must be increased to a suitable value within the ims of he capability of the particular material. lis desirable ta form these specimens wihout the necessity of heating ag this wil macy the results Figure 14—U-Tension Test Jig I Lene ) Figure 15—Pull Test (90-Degree Peel Test) 36MOMENT ARM AWS C1.1MC1.1:2000 STATIONARY 0 0 Gee LOCKING HANDLE \ n (HOLDS GATE IN PLACE) SPOT WELD ~ CENTER AS SHOWN, 50 mm : FT g7iny | [+ 50 mm x} raring Figure 16—Test Specimen and Typical Equipment for Torsion-Shear Test 37‘AWS ©1.1MIC1 1 :2000 steels, was found to be approximately iwice the tension shear stress. ‘An additional benefit of torsional testing is that it also allows the determination of tension shear strength by using the following equations: S.= 28, (Eq. 1) where ‘S= tension shear stress Me _ 2k. pee ee (Eq. 2) Taaaa (Bq.2) where L = straight shear load cross-sectional area A Substituting wimate tore (T) for torgue M, and L for sight shea load, 1 aL 2 ltmate torque [Nm in, pounders) ‘weld diameter [m (in.)} eee “The above formula gives the approximate relation be tween shear strength and torque required to shear the veld thereby pemiting evaluation ofthe shear tenth by torsional testing, o by clelating theultimate torque from the set loa, ‘When tested and computed as indicated above, the sengh values for single spot welds may be determined 4.9.5.1.5 Impact Test. The impact test dfferen- tiates between degrees of weld resistance to fracture under impact load. Five types of impact tests are de- scribed here! 495.15.1 Tension Shear-Impact Test limited to thicknesses up to 3.2 mm (0.125 in). A satis- factory shear-impact test for spot welds may be obtained bby using the 51 x 152 mm (2 x 6 in.) tension shear speci- ‘men (see Figure 8), and a modified 50 to 100 N (II to 2 pound-force) pendulum-type impact testing machine. ‘To satisfactorily test welds in sheets up to and including 3.2 mm (0.125 in.) thickness, it is necessary to have pendulum bobs of different weights In this type of test, the specimen is held by serrated ‘wedge grips in the special pendulum bab and eross-head attachments. When the machine is operated, both the cross-head and bob, which are connected by the welded specimen, fall unti the cross-head is caught by adjust- able anvils at the bottom of the pendulum swing. The pendulum bob is free to continue its swing, and will do so, provided sufficient energy is available t fracture the specimen. The residual swing of the pendulum indicates the impact loed, in newton-meters (foot-pounds-force), necessary to break the weld. Care should be taken to properly tighten the wedge grips so that no errors are in- troduced by slippage of the specimen during the test. If rip slippage is a serious problem, pin connections may be used to supplement the grips. The striking surface of the cross-head and the impact-receiving surface of the anvil should be perpendicular to the longitudinal axis of the specimen to preclude errors caused by twist load. Tests may be made at various velocities which should be not less than 3 m/s (10 fs) or more than 6m/s (20 fs). ‘Velocity should always be stated as a maximum tangen- lial velocity of the eross-head striking surface. ‘The im- pact value should be taken as the energy absorbed in breaking the weld, and is equal to the difference between the energy in the entire striking unit, which may, for ex- ample, consist of pendulum, pendulum bob, specimen the instant of impact withthe anvil and 1g after breaking the weld. For maxi- ‘mum energy, the kinetic energy imparted to the tooling should be taken into account. Similar to the requirements for tension shear test, itis desirable to determine and report the bending angle at fracture as measured after the test. ‘When making shear-impact tests, some of the energy is absorbed in plastic deformation of the sheets. In order to control the extent ofthis deformation, the distance be- tween grips should be not less than 125 mm (4.9 in.) nor ‘more than 129 mm (5.1 in). ‘Since large changes in spot weld impact strength ‘occur with relatively small changes in sheet thickness and weld size, the coverage obtained by any one pendu- umm bob assembly is limited, 49.5.1.5.2 Cross-Joint Drop-Impact Test. Since the range of the ordinary pendulum-type impact testing machine will not permit tension shear impact tests, to be made on spot welded sheets of thicknesses greater than 3.2 mm (0.125 in.), a different procedure must be used to apply impact loads to welds in the heavier gage metals. The most critical direction in which an impact load may be applied to spot welds in heavy plate is in a direction normal to the plate surfaces. This may be ac- ‘complished using a test specimen similar to that used for 58AWS C1.1M/01.1:2000 IRs cross oin tension test with added reinforcement as amount of frition may be controled by means of spring- shown in Figure 17. loaded machine screws. An arm on the aluminum push ‘he principal components of a drop weight impact rod provides a convenient place for an indicator fart machine are a vertically guided, free-falling weight, a gauge 10 be used to measure the maximum deflection at Tidly supported anvil, and a pair of calibrated springs the springs (see Figure 18). A calibration eure for ete Paced below the specimen or other type of force trans- ual energy may be obtained by dropping the weight from dcer arrangement fo measure the remaining energy of _various heights corresponding to varius pola ener the weight after the weld fractures (sec Figure 18). The gies of the moving system. ower portion of the weight is designed as a fork to as- ‘The results obtained with the eross-joint drop-impact scot e impact ofthe weight willbe applied equally test are subject to two types of envoy Boh ok een to both sides of the lower plate ofthe specimen. The concerned with the behevior of thine, plates and the {rath ofthe opening between the wo prongs ofthe fork softer types of steel. One source of roan eke inability ofthe weight is made 79 mm (3.12in.).3 mm (0.12 in.) to restrain the lower plate again bending. In this case, if Sreater than the specimen plate width of 76 mm (3.0 in.) the lower plate is thin and oft, too mack bending will be or he Tork alu clearance between te inside surfaces produced, and either the specimen will nor es org of the fork and the clamped upper plate large portion of the impact energy will be absorbed in jen calibrated springs are used to measure the re- bending of the plate. Although the ability of weld ra the aa cnerBy after the tet, the maximum deflection of force the plate to bend may be & good indication of weld the springs may be indicated by an aluminum push rod quality, the resultant impact energy aimortad by bending moving between a pair of bronze fiction plates. The will not be a good measure ofthe Weld stengeh On te #2 —___ eo He 56 ba 75, 6 a 25) 80) (25) b+ 8-H 38 >} 13) Ps) t 64 23) 1 Lok Ne = eae ae 21 ‘ O-1-S m 98 (1.5) 25) BRACING PLATE — SAME THICKNESS AS BOTTOM PLATE 4 DIMENSIONS SHOWN ARE IN mm (in) Figure 17—Drop-Impact Test Specimen 39‘AWS C1.11401.1:2000 DIRECTION OF LOADING Figure 18—Drop-Impact Test Machine other hand, severe plastic deformation of the plate mate- rial in the vicinity of the weld is a much better indicator of weld quality. Therefore, plate bending at some dis tance from the weld should be avoided. The second source of error in impact testing is bending of the upper Plate and slippage ofthe specimen in the clamps. Both of these cause absorption of additional energy, and a true ‘measure of weld toughness is not obtained. In order to avoid the possibilities for the errors men- tioned above, two methods may be used to minimize bending and grip slippage in the upper plate. Onc is to provide serrated jaws for clamping to prevent slippage. The other isto place another plate directly over the upper plate and to attach these plates at their ends by additional spot welds, as illustrated in Figure 17. In this case, the extra plate is in compression during the test, preventing excessive plate bending due to grip slippage. In the test- ing of a thin plate welded to a thicker one, the heavier plate is arranged to be struck by the falling weight. The precautions as mentioned above should be used with the ‘upper plate to ensure a satisfactory impact test. If both plates are thin and soft, it may he necessary to reinforce the lower plate in a manner similar to that used to stiffen the upper plate. 49.5.1.53 U-Specimen Shear-Impact Test. This test utilizes the specimen made by joining two U-shaped sections back to back by a single spot weld as shown in Figure 13. The specimen is dynamically loaded in a pendulum type impact testing machine with atleast a 300 Nm (220 foot pounds-force) capacity. The test fix- ture is so designed that the force applied in fracturing the specimen is essentially in shear as shown in Figure 19. ‘The operation of this testis similar to that described for the tension shear-impact test. The energy (Nm [foot ounds-force]) consumed in fracturing the specimen and the mode of failure are recorded. 498.154 UsSpecimen Tension-Impact Loading Test. This test also utilizes the U-shaped test specimen shown in Figure 13. In this case the test fixture is so designed that the forces applied in fracturing the specimen are in tension as shown in Figure 20. In all other respects, this testis the same as the U-specimen sh ‘impact test. 49.5.1.85 Instrumented Impact Test. The instrumented impact test electronically records the load versus time and the impact energy versus time traces to follow the dynamic fracture process of the specimen. The instrument consists of: (1) Load transducer placed on the pendulum bob to sense the specimen loading, (2) Electronic signal conditioning circuit, and (3) Graphie recording equipment for plotting the transducer ourput versus time. For certain alloys and specimen configurations, load signal oscillation may occur and become excessive. The accuracy of load values is assured if sufficient damping is achieved. For an accurate determination of the peak load, it should be required thatthe time to the peak load is atleast three times the period of the oscillation, 49.1.6 Fatigue Test. The fatigue test is per- formed using the shear test specimen (see Figure 8). The specimen is mounted in the fatigue tester using utmost ‘cure to align the weld with the force center. Fatigue tests of spot and projection welds aré often conducted with a ratio of minimum stress to maximum stress of 0.1. Maxi- ‘mum tensile load should never occur at less than 25 per- cent ofthe machine's operating range. There are different ‘ypes of fatigue testing machines, such as the (1) me- chanical (eccentric crank, power screws, rotating masses) ‘ype, (2) hydraulic or electrohydraulie type, and (3) elec- lromechanical or magnetically driven type. A typical fa- tigue test set-up is shown in Figure 21 ‘The selected fatigue testing machine should permit cycling between the intended stress or strain limits. For constant-amplitude low-cycle (less than 105 cycles) fa- tigue, the machine control stability should be such that the respective stress or strain limit is repeatable from cycle to cycle to within 0.5 percent of the average control limit and repeatable over the test duration to within 2 percent 60AWS C1-1MIC1.1:2000 «E}-- - » vos \ ATTAGH TO eeRBULL Boe Y CroRstEN Figure 19—Test Fixture for Shear-Impact Loading Test ATTACH TO. PENDULUM 608 ATTACH TO (CROSSHEAD Figure 20—Test Fixture for Tension-Impact Loading Test Of the average contol limit Ether strain rate oF fre~ times to within 2 percent ofthe machine operating range auency of eeling should be constant for the duration of Below a eertain frequency (eg. 170 He depending vy tach test. Although constant strain rate testing is often the metal), the fatigue effets dst requency we nesta breferred, and is experimentally more tractable than con- gible. Above ths frequency, the effet of inequenes on Stant frequency esting, the later may be of greater prac- the fatigue strength may be signineant and chee te ce tical significance to the fatigue analysis of resistance ported particulary if the materials are entin nc eens eles for certain applications. In high-ycle fatigue tests, tive. Asin the tension shear test, the rotation (elec) the tet loads should be monitored continuously inthe angle (Figure 9) ofthe weld interface should be rate early stage of the test and periodically maintained. (€.g., by photographs) to characterize the stress condi- ‘The machine should have minimal backlash in the tions and plastic deformation, and to correlate it withthe loading ain. The varying stress, a determined by asuit- fracture mode of the welded joint and adjacent bare able dynamic verification, should be maintained at all metal 6AWS C1.1MIG1.1:2000 OSCILLATING LOAD = Minimum axial stress [— OBTAINED THROUGH AN Maximom axial stress ECCENTRIC SHAFT y For zero minimum axial stress, R = 0 (2) Rotation angle immediately before or at failure. 4.9.5.2 Seam Weld Tests 49.5.2.1 Tension Shear Test. To determine the shear strength of a seam weld, the tension shear test specimen (see Figure 8) previously described should contain a seam weld, in place of the spot weld, perpen- } 12.45 mm “ora mm {eao"n) icon) teromn SHOULDER UNH Losmma — (oatoin) (Goan) She Thickness a > = te) | tpeorrumcn [mm a = (ny 061-076] 02-0032) | Sigh, Shower | 031 (Oi 635 (025) osi-132 | (on36-0080 | Shans Shuler | 0 ims 952 (0275 170-229 | (oos?-aane) | Swaight Shor | on (oa) 952 (0393) ‘enc Nae 1. All dimensions rn man (i), 2. The punches should be made from SAE M2 sel, Hardness Rockwell "C" 60-63 and shouldbe nite 3. See Table 32 for projection sizes 4 On aight poet, shank hardness should be 102-103 Rockwell “B." ‘5. Gis ground surface. Cy‘AWS €1.1MiC1.1:2000 Table 45 Die Button Design Data for Low-Carbon Steel Projections 0.8 mm (0.03 in) Tf ot 40.008 men (e.0002 in} 4 <0.013 mm 9 (0.0008 in} 5 RADIUS REF +0.00 0.05 mm (o.002'1) 0.76 mm (0.030 in) R (0.64 ram (0.025 in) ENLARGED VIEW OF WELD PROJECTION BUTTON DIE A 1B Rodis Re. c D u mm in) mm (in) mm (in) mom (in) mm ny 933 | 3 | 130 | os | 1.70 | oom | 229 | eo | 06 | coz 933 | 37s) | 152 | 06) | 208 | (oom) | 267 | cto) | osi | (oo32) 953 | 0375) | 173 | 06s | 244 | (oo%) | 305 | (12) | 094 | (037) 1270 | 500) | 203 | (ow) | 295 | «19 | 356 | corso | 107 | (aoe) 1270 | (0300) | 238 | (ov | 325 | cr | 406 | crs) | 119 | (ooe) 1270 | (300) | 264 | toy | 391 | crsy | 457 | corso | 132 | {0052 1588 | (2s) | 320 | (12) | 470 | crs | $33 | c2i | 145 | oosr 1588 | (0625) | 358 | cia | 4as | cosy | 610 | (240) | 170 | toon 1588 | (0025) | 422 | 16) | 653 | c2sy | 737 | 129 | 196 | coor 1588 | 0625) | 485 | i | 749 | 295 | 813 | 32 | 221 | (0087) (General Notes 1. All eimensions ae i um (in) 2 The des should be made rom SAE A-2 sts, hardess Rockwell °C" 58-62. 3 See Table $2 for projection Sizes and Table for punch design dt, 4 Gis ground surfae, 6 Foret Etsy. suc wear‘AWS @1.11401.1:2000, lun ipo ssonps Ruryion Ly “oqpns un pp samp Soro Los umppas-sucns Seta (azo) iro) ic 00) (S00) uy | wu roo =) (coo wy) at 4 4 a act a Ot us ont v tu ce) au ove sone | suas : t Honna——F-a—] (uz zul82I$ SSAIUIEIS UO SUOROeIOg BuIULO 10) e1eq UB|Seq aig pue Young 9b e1geL, 70AWS €1.114101.1:2000 Table 47 Projection Welding Parameters for Low-Carbon Steel! Projestion Size Net Welding Curent Minimo Btecose | Welding | Amps |. Minimom Stock Thickness | Diameter ] Height | "Force | Time Spacing? ‘ma (in) sam a) _|_mméiny | kN) | cyces| tow | sigh | mmiin 51-01 (0.620-0.028) | 2.67 (0.105) | 0.76 (0.030) [0.67150 | 3-4 ] 3000] 3000| 960038 | 267600 079-081 (0.031-0.036) | 3.05 (0.120) | 0.89(0.035) |0.89(200) |< | 4000} 6000 | 12.7¢050) | 467 (1050) 0.94-1.22 0.037-0.048) | 3.560.140) | 1.020.040) |1.33,200) | 5 | 5000] 7500] 19.00.75) | 5.781300) 1.27-1.55 (0.050-0.061) | 4.06 (0.160) | 1.14 (0.045) |2.00 (450) | 7 | 6500] 9300] 19.0075) | 8.01 (4800) 1.57-2.03 (0.062-0.080) | 4.57 (0.180) | 1.27 (0.050) }2.89.(650) | 10 | 7500 | 11 000 | 22.4 0.88) | 10.79 (2430) 2.08-2.44 (0.082-0.096) | 5.33(0.210) | 1.40(0.085) |4.00(900) | 13 | 9.000 | 13.000 | 26.9.4.06) | 14.46.3250) 2.54-3.10 (0.100-0.122) (0.240) | 1.65 (0.065) |496 1150] 16 | 10.000 | 14.500 | 31:8 c.25) | 17.13 850) 3.18-3.81 0.125-0.150)_| 7.11 0.280) | 1.90(0075) [6.01 (1350)] 19 _ | 11.500 | 16 500 | 38.1 4:50) | 21.35 4800) Gener Nowe: 1. This table ito be use in conjunction with Table 52 which gives the sheet hickness combination that corespond to the projection sires shown 2 Bleeodes: RMA Css 2, uneatd coe shape wih 20° bevel and face dame 3 ines the projection Same 5. Formultipe projection welding, muliply the fare and eurent by the numberof projections to be welded bu keep the welding time constant. 44 Based on single-phase nc 60 Hz equipment 5 Minimum weld spacing is measored fon enter to centri. Table 48 Projection Welding Parameters for Galvanized Low-Carbon Steel’ Blecrods® Projection Size | Minimum Net Satsacory ‘Tension. Maesal | Body Face | Eleode | Welding | Wetting | Nugget ‘Shear Thickness | Diameter | Diameter | Force | Current | Time | Diameter | Diameter | Height | strength mm(n) | mm¢n)_|_mmén)_| xd) | Amps | Cycles | mm in) | mm(in) | mmén) | kN) (0.99 (0.039)/15.8 (0.625) 9.52.0.375)| 1.11 (250) 10000 | 15] 38 (0.15) |a75(0.18)| 103 Oa] AIT G20) 1.35 (0083) 15.88 0.625)} 11.13 0.438)] 1-78 400) 11500 | 20 | 640.25) |s.54(0.218)|1.22 (0.048)| 9.122050) 1.98 (0.078)| 19.05 (0.750) 12.70 (0.500)| 2.45 (550) | 16000 | 25 | 6.4 (0.25) | 6.35 (0.250)|137 (0.058)| 12.01 (2700) 2.36 (0.093)} 19.05 (0.750)] 12.70 (0.500) 3.34(750)] 16.000 | 30 | 7.6(0.30) [6.35 (0.250)| 1.37 0.084)| 19.13 (4300) 2.77 (0.109) 22.22 (0.875) 12.70 (0.500) 4.23 (950)| 22.000 | 33 _| 7.9(0:31) |6.35 (0.250)| 1.37 (0.054)] 21.80 (4900) ‘General Notes 1, Welding parame ace applicable for projection welding galvanized low-carbon tea. 2. Welding parameters are applicable using electrode material inched in RWMA Clases 1, 2, and 2, 3. The welding elecodedesin thatthe dove parameters pply toinclag a lat ace with 20-deptee bevel Table 49 Projection Welding Parameters for Stainless Steels’ Electrode Face Welding Current iameter® {at Electrodes) (2 Times Proj. Diameter)| Net Electrode 60 Cycles A-C ‘Sheet Thickness 20° Bevel Force Weld Time | Hold Time (Approx.) sam (in.) mm (in.) kN (by Cycles. Cycles Amps 0:36 (00014) 3.2 (0.13) 13.300) T 15 4500 0.53 (0.021) 400.16) 22500) 10 15 4750 0.79 (0.031) 4.8 (0.19) 3.1 700) 15 13 5150 1.12 (0.044) 6.4 (025) 3.1 (700) 20 1s 6 000 1.57 (0.062) 7.9031) 5.3 (1200) 25 15 7500 1.98 (0.078) 9.51037) 8.5 (1900) 30 30 10.000 2.39 (0,094) 111 (0.44) 85 (1900) 30 30 10.000 2.17 (0.109) 12.7 (050) 125 (2800) 30 45 13.000 3.18 (0.125) 143 (0.56) 12.5 (2800) 30 45 14.000 General Nowes 1. Types of set: 309, 10, 316,317,321, 347, and 39, 2, Bletrode material: RWMA Class 2, 3, or 12 1 ‘ele rr wh estos. Le waterAWS C1.1M/01.1:2000 Tabl le 50 Projection Designs and Process Requirements for Annular Projection Welding Some Representative Light-Gauge Steels Projection Welding of Low Carbon! Steel? 0.28 mm 0 0.48 mm (0011 in. 10 1019 in) Thickness (Two Equal Thicknesses) Tensile Shear Sength® Minimum Exch Projection Minimum | “Contac. | wetg | Electrode! | Welding? Thickness | Spacing Overlap | Time Force Current One Two oF More amin.) | mmn) | mmciny | cycles | KN) ‘Amps kN (by kN ab) 02801 | 7903 | 64025 6 050.(110), s200 | 085 (190) | 0.65 (145) 0.480015) | 790031) | 64(025) 6 1.00 (225) S400 | 1.78 (400) | _ 1.25 e280) (General Notes: 1 Low-carbonstel—SAE 1010~290-380 MPa (42-55 ksi) ahiate tril strength 2: Surface of tee may be oiled lighly bt Fee fom grease scale and di. 3. Based on 60 He, 4, Bleed fore conuins no Factor to further form poly mae pats 5. Stang values shoe ae baked em experience of member compan 6. Approsimatestengih per proecon- “depends on joint design welded in a butt joint and have similar shapes and cross- sections. The two piece are clamped in current conduct- ing dies which form part of the electrical circuit of the machine. Light contact is made between the pigces, and a high current is established through the circuit, causing local points of contact to be heated beyond the melting point Proper flashing action is maintained by moving the work together at a controlled rate. When the surfaces to bbe joined become sufficiently plastic, they are rapidly forged together under high force, displacing the hot ‘metal in the form of an upset. The molien metal is ex- pelled resulting in a solid-state joint. This upset action, addition to producing the weld, closes all eraters formed uring flashing and expels oxides and impurities from the weld. 6.2 Equipment. Welding equipment varies in the meth- cds used to conduct the welding current and apply the welding force to the workpiece. All equipment must be capable of bringing the workpieces together in a con- trolled manner and automatically regulating the feed of the workpieces (rate and distance of travel), the second- ‘ary voltage and current and the timing of the application of current and upset force. 6.2.1 Platen Feed. The platens must be advanced to- ward each other in order to maintain flashing, Manual flashing should be restricted to less than 15 percent of the total flash time. Automatic flash feed may be effected by cam followers, servo motor drives, hydraulic actuators, 7 ‘or pneumatic controls. A constant acceleration will pro- vvide increased heating with reduced material loss. 6.2.2 Secondary Voltage and Current, The second- ary voltage during flash time may be contzolled by means of taps on the Welding transformer, Phase shift control should not be used to control flash voltage or eur- rent. During upset or postheat, phase shift control using silicon controlled rectifier (SCR) or ignitron tube con- trols may be used to adjust current. 62.3 Timing, Upset current and force timing may be controlled by means of cams, limit switches, or elec- tronic controls. Flash time is to be controlled by the platen feed system. 6.24 Electrodes. The electrodes should be of ade- quate size and should be so fitted to the surfaces of the workpieces to be welded that alignment of the workpiece cross-section is properly maintained and the necessary current will be uniformly distributed about the contact, surfaces. The electrode material should be capable of conducting current to the workpieces without damage ue to localized overheating. 6.3 Welding Variables. Flash welding involves a large number of variables. These variables are listed and de- fined here along with a variable definition chart (see Fig- ures 27 and 28) and not in Terms and Definitions (see Section 2). It should be realized that not all equipment nor all welding schedules can use all of these variables. 2‘AWS @1.1MiC! 1 :2000 Table 51 Projection Welding Design Data for Stainless Steels"? “B, 7l aly cf ‘Eee ; Minimurn Shear Sength {Single Projections Only) ‘Thickness T kN aby ofThimest | Diameter of | Height of Minimom | Minimum Outside Piece | Projection D | Projection H | Tensile {Tensile Strength] Tensile ‘Nugget | Contacting (Nominal) | (See Notes 7. | (SeeNNotes 7, } Strength | 480MPa | Strength | Diameter | Oveclap (See Notes 1,2] Band10 | 9, and 10 Below | (704si) Upto | 103GPa | (at Weld | (See Notes s 3.and 4 below}] below) below) 480MP2 | 1.03GPa | (130ksiy | Interface) | and 6 below) mm (in) | mm in) | mm (in) (7Oksi) 504s) | and Above | mma) |” mm in) 0.25 @010) | 1.40 (0055) | 038.015) | 0370130) | oso | 1a1es | 2480.12) 320.13) 030(0.012) | 140(0055) | 0.380.015) | 0.76c170) | 098220) | 147630) | 248.112] 321013) 0.360.014) | 1.40(0055) | 0.38 (0.015) | 089200) | 1.25280) | 1690380) | 2480112] 320013) 0.41 (0.016) | 1.70(0067) | 0.430.017) | 1.0740) | 14730) | 2o0(450) | 2a8@.112] 4010.10) 0.53 (0.021) | 170(0067) | 0.430.017) | 142G20) | 1.96(440) | 267(600) | 336(0.140] 4.0(0:16) 0.64 (0.025) | 2.06 (0081) | 051 (0.020) | 200430) | 2.67(600) | 3.65(820) | 336(0140)| 4800.19) 0.79 0.031) | 2.390094) | 0.560.022) | 2.820630) | 378(@50) | 4s9crio| 429(0.16)| 361022) 0.86 (0.034) | 2.39(0.054) | 056(0022) | 351790) | 445 1000) | 5.781300) | 429(0.169)| 5.60.22) 1120.04) | 3.02(0.119) | 0.71 (028) | 4.09620) | 5.781300) | 8902000) | 429(0.169)] 7.1 (028) 1.27(0.050) | 3.200.119) | 0.71 .028) | 6.01 (1350) | 7'56(1700) | 10.68 (2400) | 5.72 (0225)| 7.1 (028) 1.57 (0.062) | 3.960.156) | 0.89 (0.035) | 8.67.1 950) | 10.01 (2250) | 15.12 400) | 5:72(0225)| 9.5037) 1.78(0.070) | 3.960.136) | 0.89(0.035) | 10.23.2300) | 12.45 (2800) | 18.68 (4200) | 7.14 0281)| 9.5 (037) 1.98(0.078) | 425(0.187 | 1.040081) | 12.012 700) | 1.42200) | 21.35 (4800) | 7.14 (0281)| 11.1 044) 2.39(0098) | 5.54(0.218) | 1.22 (0.048) | 15.34(3.450) | 17:79¢@000) | 27.13 6100) | 7.140281) 127030) 2.770.109) | 635(0.250) | 1.37 (0.054) | 18.464 150) | 22.24.5000) | 31-14,7000) | &59(0:338}| 16.00.83) 3.180125) | 7.14(0.281) | 1.60 (0.060) | 21.35 (4 800) | 25.35 (5700) | 35:59 8000) | 8.59(0.338)| 17.5.0.68) 3.36 (0.140) | 792(0.312) | 1.67 0.066) | 2669(6000) | — — | — | ant @aay | 1900.75) 3.960.156) | 8.71 (0.343) | 1-83 (0.072) | 33:36(7 500) | — — 127 (50) | 20.6(0.81) 434.171) | 952(0.375) | 1-98 (0078) | 37.81 (8500) | — 143 056) | 2287) 4.75 (0.187) | 1031 (0.406) | 2.16 (0.085) | 4448 (10.000) — — | — 143 056) | 238 ¢098) 5.16(0203) | 11.10(0.437) | 231 (0091) | 53.38(12000)| — 160 (0.63) | 2540.00) 6.35 (0250) | 13.49(0531) | 2.790.110) | 66.72(15.000)| | — 175 (0.69) | 3180.25) (Gener Notes 1 Stiles see ypes: 308,310,316, 317,32, 347, and 349. 2. Material shoul be free fom scl, oxides, pa, grease and oi 5 Size of projection nonmally determined by thickness of iane piece, and projection should be on thicker piece where possible ' Dama sed on thickness of thinner sheet nd fo wo thicknesses ol). 5. Contac overlap doesnot clade ay ai from forming et 6. Weld should be located in enter of overnp. 7. Projection should be made on piece of higher conductivity wien dssnilar met ate welded, 8 For diameter of Projection Da oterance of 20.08 mm (0.003 in) in material pod incloing 1.27 mam (0.00 in} in thickness td 40:20 mm (20008 in. in material over 1.27 mm (0.050 in) in thickness maybe allowed, 9. For weigh! of Projection H a taerance of $0.05 (20.002 in) in material up to and inluding 1.27 mm (0.050 in) in thickness and 0.13 rm (20008 n) in material over 1.27 rum (0.050 in) in bicknese maybe allowed, 10, See Table 46 for data on punch and die designs Tor making projections. B cece enamovaue weesAWS C1.1MIC1.1:2000 Table 52 (Page 1 of 2) Projections for Low-Carbon Stee! FOR BUTTON DIES FoR PUNCHES MINIMUM SPACING SEE TABLE 45 SEE TABLE 44 fae 10.2 mm (0-400in) OR 20, fa WHICHEVER IS GREATER N | 14120 a3 MIN. H £0.05 mm 976 mm F (coven) (0,090 in) “0:10 mm 264mm (0.008 mn} (0.025 in) “ack | Tak & | G5 |_|ss2 oro} corso) 356 0x2] 292 «1n5|274 9] 244 cas) 208 oem] 79 qn 135 (2061) agi os: fo na Toya] 336 40] 36 a] 3 a0) sos wan] 20s wo] NE RD ce oe] is taoan] ite oan tap (bap ite Yaowo] 089 (nosH| as (43s) O89 (eos 97: | ass [o 06 (o140)] 336-340] 36 140) 336 «40 0° ar20]305 129} 3u8 2m Go| oz 8 is {odo} tae (nto ap (aeD] tae Yaowd] ox (hos ago (233) A89 (ts a6 | 0g [> 406 140/336 140/355 «140/336 eo] 305 orn] x05 x20] 305 e129 sof is (80.0) Vas oay| oe ao} tae eonfoss (ass ass (om89| 0 (om) om | on Jo «oxen 406 (o140/356 140/336 140/36 «aol 305 320] sas x20) 05 i coin) {ios ti {Soin iat (ey| ar (now) tae qoaass (ass|ans (on09] 08 (edn) 931 | 07» |p «oxen 406 vo140]356 340356 140/336 axa} 305 cin] 05 «x20 55 209 (Goto |] 8 ‘hosts {ena ie (coat {Dowd (Oows asp (Bia de> (8539) 089 (0) van | 09) To 010] 405 e140) 136 40) 336-0 40] 336 «.140) 305 0120) 05 (120) 305 (120 om] 8 ‘ios {coun ta feoan| oe toot ie (howls (amas (ons 122 | 308 [0] ‘oxen } 05 igo] 336 «1a0) 336 0.40] 336 «ie0) 96 OU]ase (a0) 100i |car] {i049} {noén] fa foam] Loe (oo) Ie {so} Los (oo tas (obaD| kat eo, 135 | 120 || aye] qunass ai0lss6 oxo) 336 aol ola 10] 356 010, ats) {cose} ita {coin a foap| ae oct} te (oo Los oan] ta (oB0| Le oN 12 | 600 [0] ‘o1e0| so (ciao 20% «aol 0¢ oreo] +05 el <0r wales co] sce «seo 206) a090] 8 {ots {nots ite mss 124 aos L14 (oat 124 (aoe 18 fuss} at (noe 10 | as 10] 10,10) 405 crs am 0] o% cua} 0 wie .2asn cis] {00138 {0049 te 00} te {Bors} 18 00) 191 | 223 [blast oo }as7 o1epfesr ‘0190] .0it9|(o050] 8 [127 (Oost Gear {cos 229 | 208 Jo [ss zip ls3> o210]s20 oan] sm wag]sas Ga1o}sa3 0210 Gti] 9 (0035 | (ans) 140 (089140 (04590 (aS 130 (Oe a8 20 | a4 [b|s2 o20/s33 020/833 a2i0]s3 ca]szs oaio]s3s @an]s33 ai0} 16106] 095) [130 (0085)| 40 (003540 (0035140 (0035) 300 | 234 [a[ew w2sple 10 onofci9 O20) «1 Gaw]e0 Goalie 020] itp] 00) it] es (is) |e (0 ss (00s) ts5 (0) toeed| es Odea 28 | 222 [pew w2.a/e.0 oxo] 10 229] 519 w249| 610 e240] 10 o2i0] Gido|its] ARG W085] Les (O03) tes (os Ls teas) a8 (Oued 48 {2as3} 335 | 210 [pe w2mlei0 20] 10 20] 010 G240) 619 aaa es0 « ain) isa] eb1z0] RN (ies) | es (0035s (ab Las (00) 8 OED] ts {c033) 3ai | a6 [ppm ozo lr oman] 10 9220] 630 240] 10 ‘oai0) cisco) [ist tory| 131 i) 63 (aes ts (089 tas {iss} 406 Jan [pfs o2so/71 2a) 12 0240] 610 210] 10 020] ctgy|ots) [st tarts (or) 48 fans} ts {69} as {oas5] 427 | «22 [pss oan} 20) 30 0249] 610 e200] 10 0210] city} or) | 26 oa] (or) 143 {es} tas {0089} Las {bass} ‘Genera Net 1 Sx Tal fr punch deg at, Tbe 4 ere desen dasa Table 47 for welling cbs. 2, Wheat bikes rt the pees be weeds x rete pj shoul bon he cher pee. 5, See WMA for aden formation o avi niger wn Rly Wo ents ne Bae gcaoy, Us msera2AWS C1.AM/C1.1:2000 Table 52 (Page 2 of 2) Projections for Low-Carbon Stee! FOR BUTTON Dies FOR PUNCHES Minimum SPACING SEE TABLE 45 SEE TABLE 44 aie 10.2 mm (0.09 in) OF 20, al WHICHEVER IS GREATER 14120 pont MIN 140.98 san 076 mm & {0.002'in) 1D (.030in) 0.10 mm 64mm (0.008 in} (0.025 in) Nom ] Min Tek | Ek sunita] | 137 @0s0|122 aos] 109 coi] 914 easoy| 07 10025] 046 02]o56 02] 051 om Gai | 031 Po | sas 1am] sme crnnPaar wo105] 267 coon | rar ‘@x05] 267 a0] 267 ia] ae 10H om] 00] w Las tonss|os9 ass) ar (omn| 0% qasn| 74 {010 | 0% (oo3m} % (oa%)|a% (0s an | 036 Fo ]30s 120] 308 arzm] sr (o105] 267 co) | 267 10,05] 267 10105] 267 0105] 267 Cros coor] omy] i [os (aaa [oa comsifo% (as a% (Don | 076 fea] 076 (0030 | a7 ow |a%6 om) o76 | 066 [> ]30s 120] sas w1r0f2«7 (0109) 267 (105 267 (0105) 267 10105) 267 cosa) 267 (rosy caso] om] [099 (38) | 089 (oms}f% fom) a7 (Dax | be {0030 0% (00%) 076 (00%) | a%% (03 asi | on Fo |30s 1am] 30s .20fsr (u109] 267 «105 267 ‘@109] 267 0105] 267 axa5]267 105 cosy] om| 1 [089 (3s [os (omsfors toon} {030 0% (G01) 0% (00%)| 0% (oa ani | a7 Fp [30s iam] 30s «i20) sos or] (0109) 247 a105] 257 0105] 26" e105 cos cos] 1 [as aoss [p85 ass} 9 nos | 089 {ea | 37% ‘00%0| are | o%8 (om) iar | aai | > [305 ax [05 ca120) 305 (0120) 305 e309] 267 105] 267 aa] 267 105 coor] oa36| 1 [099 (0 [ox (om | 089 ‘50% | 085 {0000 0% 0030] a7 (aa%)| 0% (1s) 12 | 19 [> fase ca co129 [305 | g 8 a i 4 > 2 % 5 Fi 8 g . — 4 8 é 2 g 3 8 a 8 g 8 5 5 LU LJ ‘rave ary, iNmaL = AWS G1.1MW1.1:2000 MATERIAL x 77 ARTERIALY, WATERIAL//iMaTeRIALY | wanuaL LBeT wip tot | FLASH OFF] f= I~ AuTOMaTIC | 7 som reasnorr I || WELD UNE UPSET tH) row—"+| |" \ FLASH OFF (F) g TNE —— MATERIAL x S INTIAL EXTENSION (C) IS MATERIAL Y ON INITIAL EXTENSION (M4) Nose oF Die ON MOVABLE PLATEN AT START OF WELD DIMENSIONS Figure 27—Chart of Flash Welding Definitions 9AWS .C1.18C1.1:2000 ppeveat vurser w ( FoRce FORCE ® 1 1 PREHEAT ueser CURRENT FLASH euasH current] ) postmear Oren CURRENT CURRENT ary Ae 5 ) \ 3 UPSET CURRENT TIME” J time ar vy) —>}+ time ar Vp |-————+| — wanvat “FLASH Time fp PREHEAT |. ____aurontaric FLASH TiN THe ———-Fasit ive: pp -weio timer }_ wens rerion — —_____.| Te —> Figure 28—Chart of Flash Welding Definitions preheat foree (newion {Ib-l) i the force exerted on the travel at I (Q, mm {in.) isthe dimension the movable welding surfaces during preheating. platen (Material Y) travels during Mashing current I, ‘preheat time (5) is the duration of preheat curent flow travel at La (R, mi fn.) is the dimension the movable during the preweld interval platen (Material Y) travels during flashing current secondary voltage (rms. V)is the open-circuit voltage of upset current time (s) isthe ime during whieh upset: the welding transformer measured on the secondary ting current flow is taking place side with no phase shift ‘upset time (3 isthe time during upsetting spring-back (mm) {in.) is the deflection of the welding Se ee ee eae upset voltage (rms. V) is the total rms voltage that oc- cours across the workpieces during upsetting. time at flash eurrent 1 (5) isthe time during which weld fine is the plane of fusion ofthe welded part. flashing with current I, is taking place. weld time (3) isthe time during which flashing and upset time at flash current I; (s) is the time during which are taking place. flashing with current Iy is taking place. upset force (newton [Ib-f]) is the Force exerted at the total flash-loss (D, mm [in.} is the total length of mate- Welding surfaces during upsetting, rial that is consumed in flashing, upset current (rms. A) is the total rms current impulse {otal upset (H, mm [in.}) isthe length of material that is or series of impulses that occur through the work- consumed as a result ofthe forging action. pieces during upsetting 806.4 Welding Variable Measurements 64.1 Dimensional Measurements, The dimensions below are usually obtained by scale measurement of the ‘workpieces before and after welding, (1) Material X toss (2) Material Y loss (@) Initial Extension—Material X (4) Initial Extension—Material Y (6) Final Extension—Material X (6) Final Extension—Material Y ‘The following dimensions are usually obtained by seale measurement of such items on the welding machine. (1) Initial Fixture Opening (2) Final Fixture Opening (3) Total Flash-toss, (4) Manual Flash-loss (5) Automatic Flash-loss, (©) Preheat loss () Travel at Initial Current (1,) (8) Travel at Flashing Current (1) ‘The Total Upset (H) may be measured by subtracting the sum of the measurements of Total Flash-loss (D) and. Preheat Loss (G) from the measurement of Material Loss ©. 64.2 Time Measurements. The following time inter- vals may be obtained by direct measurement with a stop- watch, or can be obtained from an instrument such as an oscillograph, recording ammeter, recording wattmeter, or ‘welding monitor, () Preheat (2) Manual Flashing. G) Automatic Flashing (4) Time at Flash Current (3) Time at Flash Current I (© Welding Cycle (D) Quench or Cool (8) Postheat (9) Clamp Holding 643 Force Measurements. The Platen Force and Upset Force are of a transient nature and are influenced boy the method of applying the forces, and by frietion, iner- tia, and the opposing reaction of the material being upset. Consequently, itis difficult to obtain precise measure- ‘ment of such forces without strain gauges or load cells, ‘The Clamping Force is usually caleulated, the effect of friction being considered when making such calculations. 64.4 Current Measurements. Preheat Current, Flash Current, Upset Current and Postheat Current can be mea- ‘sured with weld current monitoring equipment, ‘AWS. C1.1MIC1.1:2000 The Flash Current is very irregular due to the flashing. action of the weld. While an oscillograph record may Provide an indication of this current, such records are dif- ficult to analyze readily. To transfer data from one weld- ing schedule to another it is necessary to use an rms current measuring device that is synchronized in time With the current. 6.45 Voltage Measurements. Secondary Voltage can be measured with weld voltage monitoring equipment. ‘The use of average and/or peak measuring equipment should be avoided. 6.4.6 Rates and Velocities of Flash-Loss and Upset. ‘The Average Rate of Flash-Loss can be ealeulated from the Flash-Loss Time and Total Flash-Loss, ‘The Instantaneous Rate of Flash-Loss, Instantaneous ‘Velocity of Upset, and Average Velocity of Upset can be ‘measured by the use of any device which will satisfacto- rily record mechanical motion and time. 6.5 Classification of Steels for Flash Welding, The val- ues of the upset forces required for various sections of var~ ious steels are related to the temperature gradient of the workpieces in the plastic zone and to the compressive strengths of the steels at these elevated temperatures. For ‘consideration in applying the flash welding process to steels, such steels and their classes are grouped as follows: (1) Low-Forging Strength Steels. This class is typi- fied by SAE 1020, 1112, 1315, and those steels com- monly designated as high-strength low-alloy (HSLA) steels. (2) Medium-Forging Strength Steels, This class is \ypified by SAE 1045, 1065, 1335, 3130, 3135, 4140, 8620, or 8630, (3) High-Forging Strength Steels. This class is typi- fied by SAE 4340 and 4640, stainless steel (12 percent chromium type), stainless steel (18-8 cutlery type), high speed steel, or tool steel (4) Extra-High Forging Strength Steels. This class is typified by all steels exhibiting extra high compressive strengths at clevated temperatures, such as A-286 and. 19-9DL. 6.6 Joint Preparation and Cleaning. The mating parts should be prepared in such a manner thatthe heat gener- ated will be uniformly distributed over the section. Fig- ures 29 and 30 show recommended end preparation for flash welding of flat sheet, tubing, solid round, hexago- nal square, and rectangular bars Welding of tubing with a ratio of outside diameter to wall thickness greater than 30:1 is difficult and therefore not recommended. Additionally, welding of sheet with a width to thickness ratio of greater than 400:1 is difficult and therefore not recommended. 81AWS G1.1MIC'.1:2000, i INITIAL DIE OPENING MATERIAL LOST FINAL DIE OPENING = TOTAL FLASH-OFF com> exectaove 7 ble ol TOTAL UPSET k= MATERIAL LOST PER PIECE = M = INITIAL EXTENSION PER PIECE . = OUTSIDE DIA. OF TUBING. J i 3 \ ectone MINIMUM NECESSARY LENGTH OF ELECTRODE CONTACT 7 = TUBE WALL OR SHEET THICKNESS Figure 29—Flash Welding of Tubing and Flat Sheets 1} + Z| J 4 LOCATOR 4 ob. AND + i BACK-UP L 1 ‘A= INITIAL DIE OPENING B= MATERIALLOST = FINAL DIE OPENING D = TOTAL FLASHOFF Us ELECTRODE, 4 H = TOTAL UPSET J = K = MATERIAL LOST PER PIECE = MM = INITIAL EXTENSION PER PIECE a ELECTRODE 0. = OUTSIDE DIA. OF ROUNDS OF MINIMUM DIMENSION OF OTHER SECTIONS S = MINIMUM NECESSARY LENGTH OF ELECTRODE CONTACT Figure 30—Flash Welding of Solid Round, Hex, Square, and Rectangular Bars 2‘The surfaces of the parts contacting the dies and the surfaces to be welded should be clean and free from ox- ides, paint, grease, dir, or foreign matter which would interfere with the passage of current through the work- piece. Chemical cleaning and grit blasting arc preferred. Grit blasting should be followed by treatment to remove imbedded particles prior to welding. 6.7 Welding Schedules. The data shown in Tables $4 and 55 and Figures 29 and 30 are offered as a guide for developing flash welding schedules for various steels, Flash welding schedules for welding steel tubing and flat sheets having a thickness ranging from 0.25 10 25 mm (0.010 to 1.00 in.) are given in Figure 29 and Table 54 and cover steels of low and medium forging strengths. Flash welding schedules for welding solid round, hexag- ‘onal, square, and rectangular steel bars having a diame- ter, for round bars, or minimum dimension, for other shaped bars, ranging from 1.3 t0 50 mm (0.050 to 2.00 in.) are given in Figure 30 and Table 55 and cover steels ‘of low and medium forging strength, Refer to 6.3 for def- initions of process variables. ‘These schedules show the necessary dimensions for setting up a flash welding machine to weld such sections and the total flash time based on welding without pre- ‘neat. No data are given on the flash current, rates and ve- ‘ocities of flash and upset required due to the varying types of equipment used. ‘When setting up a schedule, the dimensional variables and flash time are selected from the tabulations, The ma- chine voltage regulator is adjusted to give the lowest sec- ondary voltage at which steady and consistent flashing ccan be maintained. The flash current resulting from such a voltage setting will then be at a satisfactory value. The secondary voltage to obtain this satisfactory flash current is dependent on the electrical characteristics of the weld- ing machine being used. “The upset forces used for the schedules are dependent, upon the class of steel as well as the section being welded. Experience indicates that the selection of equipment should be based on the following values of recommended platen force, and such values are based on the welding hncat being attained solely by flashing using no preheat: Low forging strength steels—69 MPa (10 ksi) of weld cross-sectional area. ‘Medium forging strength steels—103 MPa (15 ksi) of weld cross-sectional area, High forging strength steels—172 MPa (25 ksi) of weld cross-sectional area. Extra high forging strength stecls—241 MPa (35 ksi) ‘weld cross-sectional area, It should be noted that the most common applications use no preheat or dual flash currents, but consist of fash- ing at a single current followed by upset. AWS C1.1MIG1.1:2000 6.8 Weld Discrepancies and Causes. Effective problem- solving in flash welding requires a knowledge of weld discrepancies and their causes. Generally, the solution ‘becomes obvious once the cause of the discrepancy is de- {ermined. The following are typical flash weld discrepan- cies and their possible causes: (1) Cracks (usually in the upset metal) + Metal not sufficiently plastic during upset * Inadequate die opening + Inadequate weld time + Inadequate upset current Cracks totally in the upset metal are considered ac- ceptable because the upset metal is usually removed after welding, (2) Weld Misalignment * Clamp dies misaligned + Clamp dies inadequately tightened + Backstops mist + Excessive welding machine deflection + Clamp dies excessively worn + Parts misaligned before welding (3) Flat Spots, Penetrators (Oxide Inclusions) + Improper flashing acceleration just before upset + Inadequate upset force or upset velocity + Inadequate upset travel + Inadequate Mash travel + Early cut off of flash current + Enratic flashing caused by excessive flashing voltage, excessive or inadequate flashing acceleration (4) Die Bums (overheated areas in the workpiece at the location of the dies) + Insufficient contact area between the die and the ‘workpiece for the magnitude of current being passed + Foreign material between the die and workpiece or surface contamination *+ Insufficient clamping force (5) Inadequate Weld Strength + Improper upset travel *+ Upset force too low + Parts slipped in clamp dies due to inadequate clamp force or backup + Improper flashing velocity or acceleration + Flashing voltage too high + Flash current phase shifting *+ Current shut off too soon before upset + Misaligned clamp dies + Final die space too large (aluminum welding) * Flash time too short + Defects in metal being welded 6.9 Weld Quality and Mechanical Property Tests 6.9.1 Destructive Weld Quality Tests 6.9.1.1 Metallographic Test. Metallographic ex- tion should be used to evaluate flash welded joints 83‘AWS C1.1MIC1.1:2000 sous pon uso ss yn pu gd na Bao ona He“ m9) seo Joan up 0) pans PN oat Gano) Iso. cu ae W surg Aassy 1) 62 aa 295), sjeays 1214 pue Buiqny jo Burpjem ysel4 40) Beq ys age 84 Sela harrcene is‘AWS C1.1MIC1.1:2000 samsnone ep sn std 0 98 nn up pong aL coo oe (ore) ose (os) ovzer cay we PCy we | Cy er ao Sung 0 qusesy 20) 96 ama 995 ‘sueg 1einBuejoey pue ‘ezenbg “aH ‘PUNOY PIIOS Jo BUIDIOM YSEIA 10} BEG sg a1qeL 85 PeeteAWS C1. MIGt.1:2000, for soundness and microstructure during welding proce- dure development. It may also be used as a process con- trol tool during production welding. One or more sections from a sample welded joint should be taken and polished, etched, and optically examined for acceptability. 69.2 Nondestructive Weld Quality Tests, Fluores- cent dye penetrant, radiographic, and ultrasonie inspec- tions may be performed to determine the soundness of flash welded joints. Additionally, magnetic particle in- spection may be performed on flash welded joints of ‘magnetic metals. These inspections should be performed after removal of the weld flash, Since normally specified nondestructive inspections may not adequately reveal the weld quality, proof load testing should be performed on flash welded joints for critical applications. A common proof test for flash welded rings is to size the ring to provide a permanent ‘expansion of not less than 1 percent across a 50.8 mm (2 in.) gauge length centered on the weld. The test is per- formed after removal of the weld flash. For heat treated rings, the testis performed after cooling to room temper- ature from heat treatment. The testis performed in such a ‘way that the stress is uniformly distributed throughout the ring. However, this test does not detect all defective welds. A more stringent proof test should be used where it is justified by the application, 69.3 Mechanical Property Tests. Standard mechanical property tests for evaluating the base metals ean be used for evaluating the mechanical properties of flash welded joints, ‘The test specimen gage section should be centered on the weld. For notched specimens, the notch should be centered fon the weld. Weld joints which are heat treated before ser- vice should be tested in the heat treated condition Mechanical property tests, such as tensile and bend- tests, may be performed to determine the deterioration in performance of the welding machine with time. These tests should be conducted on welded samples before, at regular intervals during, and after a production run. The test specimens should have the same cross-sectional area in the weld area as the production parts to be welded, and be of the same metal and heat treatment condition. The specimens should be tested in full section whenever prac- tical. Reduced section test specimens may be removed from the welded joint if the full section is too large to test, The reduced section specimen should contain at least 50 percent of the original weld interface area. The ‘weld flash should be removed from both types of speci ‘mens to eliminate unsound metal from the weld, 7. Upset Welding 7.1 Introduction. Upset welding (UW) is a resistance welding process that produces coalescence aver the en- tire area of faying surfaces or progressively along a butt joint by the heat obtained from the resistance to the flow of welding current through the area where those surfaces are in contact. Pressure is used to complete the weld. The ‘wo pioces of metal are similar in cross-section, Pressure is applied before the current is started and maintained throughout he joining process. Upset welding is similar to flash welding, The main difference between the two processes is there is no Mash: ing at the abutting surfaces in upset welding. 7.2. Equipment. The welding equipment must be capable ‘of bringing the faying surfaces into intimate contact, con- trolling the secondary voltage and current, and allowing the welded joint to coo! and achieve coalescence before Femoving the welding force. Equipment is available for welding: (1) Two sections with the same cross-sectional area and shape end-to-end. (2) Longitudinal seams progressively along the butt joint. 7.3 Welding Variables. Because of the similarity be: tween the two processes, upset welding has the same basie process variables as flash welding, except the flash- ing variables. The variable measurements can be the same in both processes. The flash welding variables and their measurements are described in 5.3 and 5.4, respec- tively. A form for recording upset welding data is found 74 Joint Preparation and Cleaning. Machined faying surfaces should be used because of the need for intimate contact between them during welding. For thin sheets or plates, the faying surfaces may be obtained by shearing. ‘They should be parallel when the workpieces are loaded in the welding machine. Prior to welding, the faying surfaces and those of the workpiece contacting the dies should be cleaned to re- ‘move oxides, paint, grease, dirt, or foreign matter that ‘can contaminate the weld or impede the passage of cur- rent through the workpiece. Cleaning operations that may leave a contaminant on the workpiece (e.g., grit blasting), should be followed by an operation to remove the contaminant 7.3 Welding Parameters. The data shown in 6.7 for flash Welding of various steels and shapes, except those related to producing flash, can be used as a guide to develop upset welding schedules for the same steels and shapes because of the similarity between the two processes, 7.6 Weld Quality and Mechanical Property Tests 7.6.1 Destructive Weld Quality Tests 7.6.1.1 Metallographic Test. As in flash welding, metallographic examination should be used to evaluate 86upset welded joints for soundness and microstructure during the weiding procedure development, It may also bbe used as a process control tool during production weld- ing. One or mote sections should be taken from a given sample welded joint, polished, etched, and optically ex- amined for acceptability. 7.6.1.2 Bend Test. A bend test may be used to ‘evaluate the quality of upset welds. A typical example of a bend test uses a batt joint in wire weld. The sample is bent back and forth until it breaks. The weld qui considered acceptable if the fracture occurs outside the weld. 7.6.3 Nondestructive Weld Quality Tests. Fluores- ent liquid penetrant, radiographic, and ultrasonic in- spections may be performed to determine the soundness of upset welded joints. Additionally, magnetic particle inspection may be performed on welded joints of mag- netic metals. 7.6.4 Mechanical Property Tests. Standard mechan cal property tests for evaluating the base metals can be used to evaluate the mechanical properties of upset welded joints. The test specimen gage section should be centered on the weld. For notched specimens, the notch should be centered on the weld. Welded joints which are hheat treated before service, should be tested in the heat treated condition, Mechanical property tests, such as tensile and bend- tests, may be performed to determine the deterioration performance of the welding machine wich time. These tests should be conducted on welded samples before, at regular intervals during, and after a production ran, The ‘welded sample should have the identical joint geometry as the production parts to be welded, and be of the same ‘metal and heat treatment condition. The test specimen taken from the sample should contain the full weld eross- section whenever practical. Reduced section test speci- ‘mens may be removed from the welded joint, ifthe full section is too large to test, When smaller size test speci- ‘mens are used, they should contain at least SO percent of the original weld cross-section, 8. Weld Bonding 8.1 Introduction, Weld bonding is a resistance spot welding process variation in which the spot weld strength is augmented by adhesive at the faying surface, Itis the same as adhesive bonding except that resistance ‘welds are used to hold the components together during the cure cycle instead of using autoclaves and tooling fix- tures, A paste or film adhesive is placed between the sur- faces to be joined. Resistance welds are then made using conventional equipment. Ia paste adhesive is used, the AWS Ct.tIWC1.1:2000 tadhesive should be from the faying surfaces beneath the electrodes during the build-up of electrode force prior to the application of weld current. Ifa film adhesive is used, there should be no adhesive in the areas to be resistance welded because it impedes the flow of current between the faying surfaces. Once the resistance welding opera- tion has been completed, the assembly is then allowed to cure in an oven or at ambient temperature, as recom- ‘mended by the manufacturer. Weld bonding has been employed for many years in the aerospace industry for structural applications. In high volume industries such as the automotive industry, the same techniques have been used for non-structural appli- cations involving weld-through sealers, However, there is 1 growing interest in these industries in the use of weld bonding in place of resistance welding for structural ap- plications involving both coated steels and aluminum al- Joys. The attractive features of using weld bonding instead of exclusive resistance welding are higher st shear strength, joint sealing, reduced vibration, improved stress distribution, and fatigue strength, 8.2 Aluminum Alloys. Weld bonding of aluminum al- loys has been conducted in the aerospace industry for ‘many years, and consequently, most of the data available has been generated in this area, 8.2.1 Surface Condition. The surface condition of aluminum alloys has by far the greatest effect on static shear strength and durability of weldbonded joints. The ‘oo main requirements of static strength and durability are both dependent on the character of the surface oxide and are affected by surface contaminants. The normal mode of deterioration of an adhesive bond in a hostile environment is the introduction of moisture between the bonding surfaces and the adhesive, The nature and poros- ity of the surface oxide has an affect on this mechanism. For resistance welding, the surface should be clean and have a low and consistent resistance. This can be achieved by chemical or mechanical cleaning to remove the oxide and surface contaminants as described in 4.3, However, for weldbonded joints subject to exposure to hharsh environments, such as in military aircraft, chemi- cally or mechanically cleaned faying surfaces would not hhave adequate durability. For such applications, the sur- faces should be preweld anodized. A low voltage anodiz- ing treatment has been developed, in conjunetion with an adhesive containing strontium chromate, 1o obtain the 1e- guired bondline durability for aerospace applications. This low voltage anodizing procedure is shown in Table 56. For joints not subject to exposure to harsh environ- ments, chemically or mechanically cleaned faying sur- faces may prove to be satisfactory. 8.2.2 Weld Parameters. Anodized surfaces require different welding parameters compared with chemically 87AWS C1.1MIC1.1:2000 Table 56 Weld-Bonding Surface Preparation for Aluminum Alloys by Low-Voltage Anodi Operation Materia! Process ‘Vapor Degrease 11, Tiichloroethylene ‘Vapor 60 sec, Condensed fluid 60 se. ‘Cool. Repeat until condensation ‘om part ceases ‘Alkaline Clean| “Turco 42158: 45-60 env 12-15 minutes, 68T8°C (45°-165°F) ‘Spray Rinse Cold deionized water 5-7 minutes Deoxidize ‘Amebern No. 7: Nive acid 7-8 minutes. Room temperature (Modined) ‘Agitated and filtered tank Nits acid: 11-14% by ‘Metal removal: 0.050-0.080 volume 42 (70% HNO) ‘gm on 7.5 em 7.5 em on 7075-76 Amehem No. 7: 22-25 emi. bare etched for 20 minutes with ‘Alodine No. 45: 3-3.2 mifl. ‘no agitation Alodine 12008 3.5-3.6 mil, Spray Rinse Cold tapwater| 5 minutes Spray Rinse Cold deionized water ‘5-7 minutes Anodize PhosphoriciSodium dichromate 20-22 minutes. Room temperature solution. Phosphoric acid: 9-12, Ar agitated and filtered tank mil (85% H,PO,) 1.41.6 vols for bare alloys Soatiam dichromate: 9-12 giver 09-1. volts defor clad alloys Deionized water balance Spray Rinse Cold deionized water 5-7 minutes Oven Dey ‘Circulating hot air 65°-£5°C (150° 10°F) (Gener Nae 1. These materials may be hazardous. Refer tothe Manufacturers Safety Dla Shit. ‘and mechanically cleaned surfaces. If a short duration, high current pulse, as is used for chemically or mechani- cally cleaned surfaces, is used on anodized surfaces, ex- pulsion will take place. To avoid expulsion, a long up- slope current, short forge delay time, and high electrode force should be used. Table 57 shows the difference in welding parameters for spot welding and weld bonding ‘due to the surface condition and the addition of a paste adhesive to the faying surfaces, Anodized surfaces may require a change in the spot ‘weld spacing and the electrode maintenance require- ‘ments. The high contact resistance atthe anodized faying surface promotes a high shunting current through previ- ously formed welds. Therefore, the weld spacing should be at least 1.5 times greater than that for conventional spot welding on nonanodized surfaces for the same ap- plied weld schedule. With the anodized surface in con- tact with the electrode, the electrode pick-up will be SSiarenn Ss Sere gt on greater than that of conventional spot welding for the ‘same applied weld schedule, Electrode cleaning will be required more frequently. Typical welding parameters for 1.6 mm (0.063 in.) thick anodized 7075-T6 sheets are shown in Table 58, Welding parameters for thinner or thicker aluminum alloy sheets can be obtained by adjust- ing the welding heat. Neither the weld time nor the forge delay time should be varied. However, the electrode force and forge force should be changed when a joint of different thickness is welded. The radii of electrodes should also be varied according to the sheet thickness. 8.2.3 Mechanical Properties. A weldbonded joint has much higher static and dynamic failure loading than ‘resistance welded joint due to the adhesive bonded area. Figure 3] shows a comparison of the failure load between the uncured joint (spot weld), and the cured joint as a function of the welding current. An increase of 88‘AWS ©1.MIG!.1:2000 Table 57 Comparison between Resistance Spot Welding and Weld-Bonding of Aluminum Alloys':?:° Spot Welding Weld Bonding Surface Conon Existing Oxide Removed Existing Oxide Removed, Oxide Deposited by Low-Voltage Anodizing Low Contaet Resistnee High Contact Resiance 100 miro 800 micr-chms Not Becrode Force 58 (1300) Wel, 894N (2000 1b) Wel, BIEN (300018) Forge 7.8KN (4000 b) Forge Welding Curent, 54 000 Amps 50.000 Amps Welding Tine 7 Cycles 25 Cycles Soin Sucngih 36-44 KN (800-1000 15) 22.2 (50001) Spot Spacing 25-38 mm (1-13 in) 50-100 mm =n) Genel Nee 1 ys: 204, 7095, 178,21 2 She hicks: mm (0063) 3. Adhesive mosied pon} Table 68 ———~—~S~*~S:CS*Cte Weld current increases the nugget size, which in- Typical Spot Welding Parameters’ for crete wel suength Tefal lon ofthe ued 6 mm (0.063 in} Thick 7075-76 weldbonded join is higher than tht of the spot wel an isnot affected by the weld current. This is due to the fact, that the failure load of the adhesively bonded joint is 9 ‘much stronger than that of the spot weld, because of the Electrode material RWMA Class 1 larger area of bonding, and that the failure load repre- sents the strength of the adhesive bonded joint rather than Aluminum Treated with a Low-Voltage Anodizing Process Eectrode (shank) 15.88 mm (0.625 in) the spot weld. As shown in Figure 32, the Fatigue strength sliameter | ofthe weld bonded joint is almost as good as the adhe- iewtode ip rads 150 mm (6.0) in, bonded joint, although the former has stress risers at ee the spot weld periph Net electrode force 8.9 KN (2000 18) pee Pee Forge force 17.8 EN (400016) 8.3 Other Metals. The weld bonding process can also be Fomaag we aT efor other metals, such as steels and titanium alloys. Forge delay time Seyeles ‘The advantage of increased joint strength from weld Upslope 1Weyeles from 15% 10 40% heat bonding compared with resistance welding alone will be Seeyeles from 40% t0 56% heat (48 kA reduced as the strength of the substrate increases. The Jocks qimepauy ~~ Objectives of using weld bonding for steels and titanium a alloys are different from that for aluminum alloys. Weld- Welding heat 56% (48 KA) bonding is not used for increasing joint strength but for Dowie SI SEI sealing ot moisture from the faying surface, improving acoustic damping ability, and for reducing vibration (g., in hoods, doors, and deck lids in automobiles). The Welding ime | 2 eyeles (atthe peak) Downslope 3eyeles from $6% to 32% hea 5 eyeles from 32% to 20% heat Hold time 200 cycles surface treatment for conventional adhesive bonding of Gamlnaae Stes and titanium alloys can be used for weld bonding 1, A welding control capable of varying heat at each cycle is preferred ‘of these materials. Satisfactory results may be obtained 2. Note seagh line, using conventional resistance welding preweld treatments; 89AWS C1.1MiC1.1:2000 (400) +15 000 e982 9 cunco staznors (3000) 3 14 000 2000 pecomvensen «0. O_-D> UNCURED STRENGTH (50) wetbiNG CURRENT RACE ° a 2000, ° 3 [-— minimum ai 5 an F— Mom vera a ert z 10 gs so 9 z E (200) 0 /* secrRoDe neers 4 120 8 z 7 maxim ti00 8 o “A g (0) 0 a f _ Qo LAP SHEAR seems | og —_— oventarienin | | 8 ADHESIVE: eo 5 (oy MODIFIED EPOXY 4 5 $ ii WELDING CURRENT (KA) Figure 31—Comparison of Tensile-Shear Strengths of Uncured and Cured (Single Spot) Weld-Bonded Joints of 7075-T6 Alu hhowever, the environment can affect the long term dura- bility of the joint. In either case, conventional welding schedules developed without adhesives will usually yield acceptable weld quality. For some adhesives, an increase in electrode force oF a change in weld time, or both, may be necessary, 8.4 Weld Bonding Quality and Mechanical Property ‘Fests, Various quality and mechanical property tests can bbe performed on weld bonded joints, In process monitor- ing, radiographic and ultrasonic inspections can be used to determine the quality of the joint areas. The tests de- scribed in 49 for spot welds are applicable to spot welds in weld bonded joints in the uncured condition. Fatigue testing of weld bonded joints in aluminum alloys can be performed using the test specimen show 9, Equipment Monitoring and Maintenance Production of consistently acceptable, high quality re- sistance welds requires an effective machine main- tenance program. The following is a listing of the Resistance Welder Manufacturers’ Association's recom- ‘mended periodic inspection and service for resistance welding equipment." Additional information can be found in the equipment manufacturer's manual 12. Resistance Welding Manual, 4th Editon, Resistance Welder ‘Manufacturers’ Association, 1989, Published hereby permission. 90(9500) (2000) (2500) (2000) LOAD —N (LBs) (1800) ‘5000 [ Cl ADHESIVE BONDED (1000) (600) (ma) o 108 04 Loap Rano, | TEMPERATURE = 75 1 5°F, HUMIDITY » 50 + 5% rh TEST SPECIMEN CONFIGURATION: SEE FIGURE 33 AWS G1.1M/C1.1:2000 1, FREQUENCY 0-20 He 108 108 107 FATIGUE LIFE (CYCLES) Figure 32—Comparison of Fatigue Test Results of Weld-Bonded and Adhesive-Bonded Joints of 7075-16 Aluminum Alloy DAILY: At the start of each work shift, the following items should be done: (1) Tum on the air supply. (2) Tur on the water supply. (3) Check for water circulation, (4) Check the air pressure setting, (5) Lubricate the required points daly. (©) Tum on power supplies. (7) Check the settings on the weld contro. (8) Dry cycle the equipment a few times to make sure everything is functioning properly. (9) Check all variables after a few welds, to see that the water, air, machine settings, and contactors are work ing properly. (10) Check the welds for desired quality. ‘Atthe end of each shift, the following items should be done: (1) Tum off the electrical supply. (2) Tum off the air supply, (3) After 10 to 15 minutes, tum off the water supply to the weld contactor, (4) Wipe all surfaces clean of dirt, dust, grease, oil, and water. * Pay particular attention to cleaning clamp surfaces. *+ Clean the machine and work area. *+ Dust lenses of any light fixtures, windows and doors, and transparent covers. Other system cheeks are: DAILY: (1) Cooling System * Check for water leaks and make necessary repairs, (2) Electrical System and Control + Check for chattering relays or switches and ‘make necessary repairs. + Check timers and controls for proper dial set- ‘ings according to the schedule chart. * Check for disabled interlocks or safety devices, 91AWS C1. 11WO1.1 2000 1.60 (0.068) SHEET 280 (10) 31.8 (125) aan 1 ‘SPOT WELD (FOR WELD: BONDED 31.8 (1.25) sont) | A | pouster 3.18 (0.125) SHEET GAIP DOUBLER. 4.83 (0.150) SHEET NOTE: DIMENSIONS. SHOWN ARE IN mm (in) Figure 331 + Listen for noises indicating loose secondary con- nectors or broken leads * Check for burned out bulbs and indicator lights, enclosure lights, and other illumination features, (G) Air System + Check for air leaks and repair. *+ Check line pressure and welding pressure, + Drain air Tine filters. + Check lubricator oil levels. + Feel solenoid valves for overheating—listen for ‘hum indicating improper seating of spool. (@) Electrodes and Fixtures * Check lubrication of seam welding heads. + Cheek for discoloration on water-cooled compo- nents indicating improper cooling, * Check for pitted, worn, or dirty electrodes. * Check for grooves or markings of fixture, + Check electrode and fixture alignment. (5) Mechanical Equipment *+ Lubricate as prescribed. igue Test Specimen of Weld-Bonded and Adhesive-Bonded Joints + fan automatic or centralized lubricating system is used, check for insufficient or excessive amounts of lu- bricants and adjust as necessary, + Replace access covers. * Check for broken or loose components. (6) Hydraulic System + Wipe top of reservoir * Check for fluid leaks and make necessary repairs + Check the reservoir for overheating + Listen for unusual pump noises, *+ Check pressure gauge settings. WEEKLY: + Remove all oil spots from floor in walk areas + Wash down floor in area of machine, * Check air and water leads If equipment has a standby mode, switch to “standby” (no weld) and check machine operation, After determin- ing satisfactory operation, return to “run” position, In ad- ition, the fotlowing items should be done:(1) Electrical System and Contro + Check relays for evidence of wear or looseness. (Never attempt to adjust relays as routine maintenance. Contact tension and quick operation are preset and should not require adjustment.) * Check programmable controls for unauthorized changes in the program and correct before placing back into operation * Sequence sequence. + Clean nameplates. (@) Electrode and Fixtures ‘+ Make a thorough inspection of electrodes and electrode holders. + Clean electrode or fixture holders and clamps. + Check for misalignment and realign if necessary. (3) Hydraulic System *+ Check cylinder rod locking nuts. + Remove sample of oil from reservoir and test for deterioration or contamination. (Testing interval will de~ pend on fluid used and its age. Check fluid supplier for recommendation.) * Check fluid fiers (@) Air System * Check cylinder rod locking nuts, *+ Check cylinder mounting and tighten if necessary. *+ Cheek and clean out water traps and filters. ‘MONTHLY: (1) General ‘+ Make a special check for air leaks through valve seats and cylinder packing. Inspect all hoses for unusual ‘wear and replace if required. ‘In adition, all relay and switch contats shouldbe in- spected for cleanliness and pitting. The contact surfaces shouldbe cleaned as required. A thorough visual inspec- tion ofthe entire machine its controls and all accessories should be made for loose or missing pars. Replace or tighten as required. (@) Cooling System + Reverse flash entire system to remove any accu ‘mulation of foreign matter. Verify volume of water flow. + Remove and clean strainers and filters + Replace worn or cracked hoses. + Tighten hose clamps. *+ Check water temperature and pressure. * Check water shutof solenoids for proper operation. (G) Blectrcal System and Control + Check control timing and power factor with oscil- loscope or other appropriate equipment. this equipment is not available, contact your welding machine manufac- turer and request assistance. * Check ground connections for good contact. + Tighten all terminal screw connections and visu- ally examine soldered connections ‘machine through full manual AWS C1.1MIC! 1 :2000 * Check line voltage with and without machine load. Variation should not exceed £10 percent. ‘+ Remove vent filters (if any) and replace or clean. + Check insulation for cracks and dirt accumula tion, Replace if necessary. + Clean all vacuum tubes, sockets, cables, printed circuit boards and like equipment. + Check transformer leads for eracks or spits. + Check primary grounds. (4) Air System + Remove air filter and clean, * Cheek for loose cylinder bolts or hold-down plates. *+ Check shock blocks for secure weldments *+ Check cylinders for air Ieaks and rods for score marks, * Check for excessive sluggishness or sticking of cylinder. Caution must be used when checking pneumatic cylinders, since some spot or press welding heads will descend if air pressure is removed. + Check air gauge for excessive pressure drops ‘during operation of welding electrode holders. * Check all speed control settings. Adjust and Tock. (QUARTERLY: (1) General + Use master level and check machine. Re-level necessary. (2) Cooling System + Check system thoroughly and replace compo- nents which show wear or corrosion. (3) Electrical System + Polish all secondary contact surfaces to remove ‘corrosion. Use an approved cleaning solvent. Some sol- vents are toxic and breathing the fumes can cause dizziness. Other solvents are flammable and require good ventila- tion; therefore, proper precautions should be taken. In the cease of excessive corrosion, a fine abrasive should be used, + Tighten all connections for good contact. + Check protective and overload devices, (4) Air System * Check air gauges and regulators with pressure indicator. Replace damaged regulators and gauges and those that are sluggish or need calibration. + Check regulator diaphragms carefully * Replace wom or cracked air hoses with new hoses. Be sure connections are tight. High volume, high pressure air hoses should receive special consideration, Poor hose connections may blow off and cause injury. + Clean or replace air-line mufflers, lubricators, and filters, 93AWS C1.1MIC1.1:2000 (5) Hydraulic System ‘+ If recommended by oil supplier, replace oil in reservoir with new ofl. * Change or clean oil filters. ANNUALLY: (1) General ‘A minor overhaul of the machine should be made ‘annually, probably during inventory shutdown or model ‘change-over. Remove all grease and rust from the ma- cchine and apply a coat of machinery paint. + Check for excessive wear of trunnions, bearings, and brushes, and replace worn or damaged parts. (2) Electrical System and Control *+ Check calibration of timing and adjust (3) Air System + Replace air hoses where required. When replac- ing air hoses or piping, oil the inside with a smal] amount of light-weight oil (4) Hydraulic System * Change oil if recommended or necessary, (5) Removing Equipment from Service Ifa piece of resistance welding equipment is being re- moved from service for a period of time, the following should be done to prevent unnecessary damage during the idle time: * Drain and blow out water from all cooling lines, especially: —Weld controls, including either ignitron tubes or SCR packages. — Welding transformers, —Blectrode holders, + Drain hydraulic uid, if used. + Protect all unpainted surfaces from rust and corrosion, + Protect the inside and outside of cylinders from necessary. rust, + Cover the equipment to prevent dirt accumulation. + Store equipment in adry location. 10. Safety and Health 10.1 General. This section is a limited noninclusive dis- cussion of safety and health for resistance welding. Refer to these documents for additional information: (1) ANSI 249.1, Safety in Welding, Cutting, and Al- ied Processes, published by AWS (2) The series Effects on Welding and Health, pub- lished by AWS. (3) Safety and Health Facts, published by AWS (4) Occupational Safety and Health Administration (OSHA), Code of Federal Regulations, Title 29 Labor, Chapter XVI, Part 1910, Occupational Safety and Health Standards (5) Manufacturer's literature, including Manufac- turer’s Material Data Sheets 10.2 Selection of Equipment, Select all resistance weld- ing equipment for safe application to the work intended. Give consideration to the personnel safety and health as- pects of resistance welding when choosing equipment for the work to be performed. 10.3 Operator Training, Properly instruct workers des- ignated to operate resistance welding equipment, Judge their competency to operate their equipment. Do not defeat nor otherwise disable safety devices such as spark shields, guards, dual hand controls, or sensing. devices. Maintain vigilance for others entering a hazard fous area and terminate machine operation until the area is clear and the machine is safe to operate. 104 Personal Protective Equipment. Employ personal protective equipment suitable for the work being per- Formed in the area of resistance welding equipment, Such equipment includes protection for hearing, eyes, face, head, and extremities. They include protective clothing, respiratory devices, earplugs, footwear, hel- ‘mets, and eye wear. ‘Additional discussions of this equipment can be found, in the following publications: (ANSI Z41, Personal Protection~Protective Foomear (2) ANSI 249.1, Safety in Welding, Cutting, and Al- lied Processes, published by AWS (3) ANSI 287.1, Practice for Occupational and Edw. cational Eye and Face Protection (4) ANSI Z88.2, Respiratory Protection (5) ANSI 289.1, Protective Headwear for Industrial Workers 10.5 Installation, Install equipment in conformance with NEPA 70, National Electrical Code, or its equivalent. In- stall the equipment with qualified personnel under the di- rection of a technical supervisor. Prior to production use, inspect the equipment and approve it by competent safety personnel to ensure that it is safe to operate, 10.6 Guarding 10.6.1 Control Initiating Devices. Arrange or puard initiating devices for portable and stationary resistance welding equipment such as push buttons, foot switches, retraction, and dual-schedule switches to prevent the op- cerator from inadvertently activating them. Use suitable initiating devices for automatic resistance welding ma- chines that have detection devices interlocked in the initi- ating circuit to prevent injury to personnel. 10.6.2 Spark Shields. Protect workers from the hazard of flying sparks by the installation of a guard of suitable fire resistant material or the use of personal pro- 94tective eye wear and clothing, or both. The variations in resistance welding operations are such that each installa- tion shall be individually evaluated, ‘The primary intent is the protection of all personnel in the vicinity of the welding operation, including the oper- ator. Further discussion of this topic can be found in ANSI ZA9.1, Safety in Welding, Cutting, and Allied Processes, Published by the American Welding Society For flash welding equipment, provide flash guards of suitable fire-resistant material control flying sparks and molten metal jonary Resistance Welding Equipment A General. Protect all chains, gears, operat- ing linkages, and belts associated with welding equip- ‘ment in accordance with ASME B1S.1, Safery Standard ‘Jor Mechanical Power Transmission Apparatus. 106.32 Single-Ram and Single-Point Equip- ‘ment. On stationary single-ram welding machines, un- less the workpiece size, configuration, or fixture ‘occupies both of the operator’s hands remotely from the point of operation during the machine cycle, conduct op- erations in a manner that will prevent injury to the opera- tor. Employ one or more of the following features: (1) Machine guards or fixtures that prevent the opera- tor's hands from passing under the point of operation (2) Two-handed controls ) Latches (4) Presence-sensing devices, (5) Any similar device or mechanism that prevents ‘operation of the ram while the operator's hands or body parts are within the point of operation 10.633. Multi Equipment. In multi-gun welding machine operations, when any part of the opera- tor can be expected to pass within the point of operation, stop the operations by the use of presence sensing de- vices, latches, blocks, barriers, or two-handed controls, 10.6.4 Portable Resistance Wel ing Equipment 10.6.4.1 Support System Safety. Equip all sus. ended portable welding gun equipment, with the excep- tion of the gun assembly, with a redundant support system capable of supporting the total impact load in the event of failure of any component of the primary sup: porting system. Design the system to be fail safe. The use of devices such as cables, chains, and clamps is consid. cred satisfactory. 10.6.4.2 Moving Holder. The moving holder on an RW weld gun is activated by a power device, usually a cylinder. Normally, one holder is dynamic, but guns are also available in which both holders can be activated through a mechanical linkage. Design the moving holder ‘mechanism to prevent pinch or shear points to fingers ‘AWS.C1.1MiCr.1:2000 placed on the movable holder, otherwise, provide guards, If suitable guarding cannot be achieved, the use af 1wo- hhanded control handles may be utilized. Locate these handles and operating switches sufficiently remote from the shear or pinch point to eliminate the possibility of any finger or other body part entering the shear or pinch point when the hands are on the controls 10.6.5 Flexible Automation Resistance Welding Equipment 1065.1 General, Robots and other flexible auto: ‘mation equipment to manipulate resistance welding guns present additional hazards. Generally, this equipment is a combination of portable and stationary resistance weld- ing equipment, Protect flexible automation with guards, latches, shiclds, barriers, and sensing devices. 10.6.5.2 Robots. Robots generally operate without operator initiation and are frequently installed adjacent to other robots and personnel. The robot arms can move without warning, Prevent workers in the area from enter- ing the working envelope of the robot. Contain the robot ‘within a fence or barricade that is electrically interlocked to prevent unauthorized or unsafe access, 106.53 Mobile Resistance Welding Automa- tion. Other types of flexible automation may be mobile ‘nd guided by sensors buried beneath the floor. Special precautions are necessary for this equipment by not only providing adequate signs and barriers but also on-board devices to detect personnel and terminate movement until personnel are ata safe distance, 10.7 Blectrical 10.7.1 Introduction, Electric shock from welding ‘equipment can kill and cause severe burns. To avoid elee- tie shocks: (1) Read the instruction manual before installing, op- crating, or servicing the equipment. (2) Have all installation, operation, maintenance, an repair work performed only by qualified people (3) Properly install and ground the equipment aecord- ing to the instruction manual and national, state, and local codes. (4) Do not touch live electrical parts. (5) Use only well maintained equipment. Repair or replace damaged parts before further use. 10.7.2 Voltage. Limit all external weld-initiating con: trol circuits to a maximum voltage of 120 volts rms for stationary equipment, as determined by the National Electrical Manufacturer's Association (NEMA) and adopted by OSHA. 10.7.3 Capacitors. Give suitable insulation and protec- tion by complete enclosure to resistance welding equipment 95AWS C1.1M/CH.1-2000 ‘and control panels containing capacitors used for stored ‘energy resistance welding involving high voltages (over 550 volts rms). Keep the door and panels locked except uring maintenance, Provide all enclosure doors with suitable interlocks and contacts wired into the control circuit. Design such interlocks or contacts so as to effee- tively interrupt power and short circuit all capacitors when ‘the panel door is opened. Install a manually operated switch or suitable device in addition to the mechanical inter- locks or contacts, as an added safety measure for assur- ing complete discharge of all high voltage capacitors ‘The panel box itself is considered an enclosure and capacitors located inside such a pane! box do not need further enclosure when the other requirements of this, section are met. 10.7.4 Locks and Interlocks 1073.1 Doors. Keep doors and access panels of all resistance welding machines and control panels locked or interlocked to prevent access by unauthorized persons to electrically live portions of the equipment, Keep doors or access panels locked if keys, wrenches, or other instruments are required to open them, Follow lockout out procedures as required be OSHA, 10.7.5 Stop Buttons. Provide one or more emergency stop buttons on all resistance welding equipment that hhave the following characteristics: (1) Requite three or more seconds to complete a se- quence. (2) Have mechanical movements that can be hazard- ous if guards are removed. 3) Installation and use of emergency stop buttons will not in themselves create additional hazards to persons. In the above context, sequence means the action and time required by the machine from the time the run but- ‘ons are locked in (interlocked) and can be released, until the machine stops of its own accord. 10.7.6 Grounding, The primary winding of a welding transformer may become shorted to the secondary wind- 1g, creating a potential hazard to workers that may come in contact with the secondary. Ground the welding trans- former secondary by one of the methods below or pro- ‘vide equivalent protection as in (3) below: (2) Permanent grounding of the welding secondary circuit (2) Connecting & grounding reactor across the see- ‘ondary winding with reactor tap(s) to ground. (3) As an alternative, on non-portable machines, in- stalling an isolation contactor to open both sides of the line to the primary of the welding transformer. ‘The grounding of one side of the secondary windings ‘on multi-spot machines can cause undesirable circulating ‘currents to flow between transformers when multi-phase primary supplies or different secondary voltages, or both, are used for the several guns. A similar condition can also exist with portable spot welding machines, when several units are used on the same fixture or assembly, or ‘on one that is nearby. Such situations may require use of 4 grounding reactor or isolation contactor, 10.8 Static Safety Devices. On large welding machines incorporating a platen, provide electrically interlocked safety devices such as pins, blocks, or latches to block ‘any movement of the platen or head. The intent is to re- quire the use of these devices when the machine area is, so large that maintenance or setup would require the in- sertion of more than hands into the closure area. The de- vice causes the energizing circuit to be broken and mechanically prevent movement of the platen or head under static load. More than one device may be required, varying with machine size or accessibility, but make each device capable of sustaining the full static load involved. 10.9 Ventilation. Resistance welding operations can pro- duce fumes and airbome particulates from the materials being welded as well as from the composition of the electrodes. Provide suitable ventilation to remove smoke, fumes, and airbome contaminants. Adequate ventilation ‘means enough ventilation such that personnel exposure to hazardous concentrations of airborne contaminants is ‘maintained below the allowable levels specified in Ocew- ational Safety and Health Administration (OSHA), Code of Federal Regulations, Title 29 Labor, Chapter XVII, Part 1910, Occupational Safety and Health Stan- dards." Particular attention shall be paid when elec- odes and metals being welded contain hazardous chemicals 10.10 Maintenance. Good housekeeping is essential for safety in resistance welding. Equipment and welding areas shall be kept in good, clean condition. Periodic in- spections shall be conducted and recorded by qualified personnel Necessary repairs shall be made by authorized person- nel. The operators or maintenance personnel shall report ‘any equipment defects to supervisory personnel. Use of ‘an unsafe machine shall be discontinued until safety re- pairs are completed. "Never leave tools or parts in the area of the secondary winding of a resistance welding machine. Resistance ‘welding secondary circuits develop a strong magnetic field when energized for welding. The force of this mag- netic field can forcefully propel metalic items which can ‘cause injury. 13. Avsilable from Superintendent of Documents, US. Gaver- ‘ment Printing Office, Washington, DC 20402, 96Pneumatic and hydraulic connections and lines shall be periodically checked to prevent leaks. Compressed air is generally pressurized 10 approximately 100 psi (0.7 MPa) and can propel hazardous objects if a line fils. Hy-

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