RWMA - American Welding Society
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RESISTANCEWELDINGMANUALRevised Fourth EditionRWMA
CONTENTSSection 1PROCESSESPREFACEACKNOWLEDGEMENTSFundamentals Of Resistance WeldingINTRODUCTIONRESISTANCE WELDING PROCESSESRELATED PROCESSESFUNDAMENTALS OF THE RESISTANCE WELDING PROCESSAPPLICATIONSECONOMICSDESIGN 81-91-121-181-18Spot WeldingINTRODUCTIONFUNDAMENTALS OF THE PROCESSTYPES OF WELDSELECTRODESMATERIALSWELD on WeldingINTRODUCTIONTYPES OF PROJECTIONSGENERAL PRINCIPLESWELD QUALITYSeam WeldingINTRODUCTIONFUNDAMENTALS OF THE PROCESSWELD QUALITYMATERIALSFlash And Upset WeldingFUNDAMENTALS OF THE PROCESSAPPLICATIONSEQUIPMENTWELDING PROCEDURESPROCESS VARIABLESWELD QUALITYTESTING AND INSPECTIONWELDING OF STEELUPSET WELDING3-13-33-83-124 4-14-24-84-115 5-15-35-35-75-115-135-155-155-18vii
ContentsAdditional Resistance Welding ProcessesCROSS WIRE WELDINGRESISTANCE BRAZINGHOT RIVETING AND UPSETTINGPERCUSSION WELDINGBUTT SEAM WELDINGRESISTANCE CUTTING6-16-46-106-126-146-16Section 2MATERIALSLow Carbon SteelsINTRODUCTIONGENERAL PRINCIPLESSPOT WELDINGPROJECTION WELDINGSEAM WELDINGROLL SPOT WELDSMASH SEAM WELDSFLASH WELDINGUPSET WELDINGRESISTANCE WELDS IN SCALY STOCKHigh Carbon And Low Alloy SteelsINTRODUCTIONGENERAL PRINCIPLESSPOT WELDINGSEAM WELDINGFLASH WELDINGHIGH STRENGTH LOW ALLOY STEEL (HSLA)7A7-17-17-37-117-127-137-137-137-167-176 8-18-18-38-128-128-14Stainless And High Alloy SteelsJMINTRODUCTIONGENERAL PRINCIPLESSPOT WELDINGPROJECTION WELDINGROLL SPOT AND SEAM WELDINGFLASH WELDINGSTAINLESS-CLAD STEEL9-19-19-59-89-89-89-9Coated And Plated SteelsSPOT WELDINGPROJECTION WELDINGSEAM WELDINGFLASH WELDINGviii10-110-110-510-510-5
ContentsAluminum And Aluminum Alloys11-1INTRODUCTIONMATERIAL PREPARATIONSPOT WELDINGQUALITY CONTROLELECTRODESSEAM AND ROLL SPOT WELDINGPROJECTION WELDINGUPSET WELDINGFLASH agnesium And Magnesium Alloys12-1INTRODUCTIONSPOT WELDINGFLASH WELDINGCopper And Copper Base AlloysINTRODUCTIONALLOYING AGENTSCOPPER BASE ALLOYSGENERAL PRINCIPLESSPOT WELDINGPROJECTION WELDINGSEAM WELDINGFLASH WELDINGNickel And Nickel-Base AlloysINTRODUCTIONSPOT WELDINGPROJECTION WELDINGCROSS WIRE WELDINGSEAM WELDINGFLASH WELDINGMiscellaneous And Dissimilar MetalsTITANIUMCOBALT BASE ALLOYSREFRACTORY METALSZINC AND ZINC DIE CASTINGSLEAD AND LEAD ALLOYSDISSIMILAR 215-415-415-515-5ix
ContentsSection 3EQUIPMENTMachinesINTRODUCTIONROCKER ARM MACHINESBENCH MOUNTED WELDING MACHINESPRESS TYPE WELDING MACHINESSEAM WELDING MACHINESFLASH AND UPSET WELDING MACHINESMULTIPLE SPOT WELDING MACHINESPORTABLE GUN WELDING MACHINESROBOT SYSTEMS INTEGRATIONHIGH FREQUENCY WELDINGMISCELLANEOUS MACHINESJigs, Fixtures And ToolingINTRODUCTIONWORKHOLDING DEVICESJIGS AND FIXTURES FOR GUN WELDING MACHINESHOPPER AND MAGAZINE FEEDSSEAM WELDING FIXTURESFLASH AND UPSET WELDING MACHINE CLAMPING FIXURESTYPES OF OPERATIONBACKUPS AND LOCATORSResistance Welding 617-1718-1INTRODUCTIONELECTRODE FUNCTIONSELECTRODE MATERIALSFACTORS AFFECTING CHOICE OF ELECTRODE MATERIALSSPOT WELDING ELECTRODESPROJECTION WELDING ELECTRODESSEAM WELDING ELECTRODESUPSET AND FLASH WELDING ELECTRODESPROPER ELECTRODE elding Transformers And Power Conversion Equipment19-1INTRODUCTIONELECTRICAL SYSTEMSINGLE-PHASE RESISTANCE WELDING TRANSFORMERSFREQUENCY CONVERTER SYSTEMHIGH FREQUENCY DIRECT CURRENT WELDING POWER SUPPLIESDIRECT-CURRENT POWER CONVERSION EQUIPMENT19-119-119-419-919-1119-11
ContentsWelding ControlsINTRODUCTIONCONTROL SYSTEMSCONTROL TECHNOLOGIESSTANDARD NEMA CLASSIFICATIONSUSER INTERFACECONTACTORSHEAT CONTROLCOMPENSATION AND FEEDBACK SYSTEMSCOOLING REQUIREMENTSPower SupplyINTRODUCTIONOUT-PLANT POWER SUPPLY SYSTEMIN-PLANT POWER SUPPLY SYSTEMInstrumentationINTRODUCTIONPROCESS VARIABLESEQUIPMENT AVAILABLEFluid Power SystemsINTRODUCTIONFLUIDSPRESSURE SUPPLY SYSTEMSCYLINDERSSYSTEM SELECTIONQuality ControlINTRODUCTIONPERSONNELFACTORS AND VARIABLES AFFECTING WELD QUALITYOPERATORSTANDARD METHODS FOR TESTING RESISTANCE WELDSAPPLICATION OF STANDARD METHODS FORMECHANICAL TESTING OF RESISTANCE WELDSMaintenance And ServiceINTRODUCTIONINSTALLATION OF EQUIPMENTSETUP OF EQUIPMENTMACHINE AND EQUIPMENT MAINTENANCEPERIODIC INSPECTION AND SERVICESPARE PARTSSYMBOLS AND 23-123-223-723-1424 25-14M11-1xi
PROCESSESSECTION 1Fundamentals Of Resistance Welding1Spot Welding2Projection Welding3Seam Welding4Flash and Upset Welding5Additional Resistance Welding Processes6
1Fundamentals OfResistance Weldingcharacteristics may lead the beginner to believe theprocess more simple, or more generally applicable,than is true. It is the aim of this introductory discussion to review the fundamentals of the process and todiscuss some of the more basic details.Welding is really a metallurgical process. Ordinaryiron has been described as a suspension of ferrite crystals of variable compositions in a matrix of its ownimpurities. It is this matrix of impurities that increasesthe electrical resistance of all metals which is of realimportance in electrical resistance welding.INTRODUCTIONWelding consists of the joining of two or morepieces of metal by the application of heat andsometimes of pressure.Resistance welding embraces that branch of thewelding art in which the welding heat in the parts tobe welded is generated by the resistance offered bythese parts to the passage of an electrical current. It differs from other forms of welding in that no extraneousmaterials, such as fluxes, filler rods, etc. are used;therefore, the metallography of the weld is not complicated by the addition of these materials. Resistancewelding further differs from the fusion weldingprocesses, by utilizing the application of mechanicalforce to forge the heated parts together. The effect ofthe force is to refine the grain structure, thus producing a weld with physical properties, in most cases,equal to the parent metal, and sometimes even superior.RESISTANCE WELDINGPROCESSESFigure 1.1 illustrates, in graphic form, the resistancewelding processes1 and their relation to one another. Itshould be noted from this chart that the general subject of resistance welding may be broken into two general classifications according to the method of joiningthe parts. (The same classifications may also beapplied to other welding processes).Resistance welding machines and their operationoften appear mysterious to the layman when he seesgood welds being made quickly and easily. The sameSee also the latest revision of Standard Welding Terms and Definitions, an American Welding Society (AWS) publication.1
butt seam welding 6-14 resistance cutting 6-16 section 2 materials low carbon steels 7a_ introduction 7-1 general principles 7-1 spot welding 7-3 projection welding 7-11 seam welding 7-12 roll spot welds 7-13 mash seam welds 7-13 flash welding 7-13 upset welding 7-16 resistance welds in scaly stock 7-17 high carbon and low alloy steels 6 .
the weld strength or, in extreme cases, to-tally eliminate fusion. The RWMA Resist-ance Welding Manual, Edition 4 (available at www.rwma.org), includes a collection of welding schedules for most metal alloys to provide high-strength welds while eliminat-ing major metal expulsion1. Welding at Metal E
6.3 Mechanised/automatic welding 114 6.4 TIG spot and plug welding 115 7 MIG welding 116 7.1 Introduction 116 7.2 Process principles 116 7.3 Welding consumables 130 7.4 Welding procedures and techniques 135 7.5 Mechanised and robotic welding 141 7.6 Mechanised electro-gas welding 143 7.7 MIG spot welding 144 8 Other welding processes 147 8.1 .
Tuffaloy Products, Tec-Option, NSRW, CMW, LORS, and the Taylor-Winfield Company, will be taking advantage of this special offer. Did you know that 70% of RWMA Welding School attendees are decision-makers with purchasing power, and 57% of them plan to make a purchase in the 12 months following the Welding School? As an exhibitor at the welding
American Welding Society. ( 2015). D1.1/D1.1M:2015STRUCTURAL WELDING CODE - STEEL. Miami, Fla . American Welding Society. ( 2017). QC10:2017-Specficiatoi n for the Qualficiatoi n and Certficiatoi n of SENSE Level I -Entry Wedel rs. Miami, Fla . American Welding Society. ( 2017). EG2.0:2017-Guide for the Training of Welding Personnel: SENSE Level
seam butt welding resistance butt welding flash butt welding resistance butt welding shielded unshielded other process plasma laser resistance butt welding inert gas welding submerged arc welding atomic hydrogen shielded metal arc welding (coated electrode) esepl w w w . e u r e k a e l e c t r o d e s .
the welding processes most often used in today's industry including plasma arc cutting, oxyfuel gas cutting and welding, Gas Metal Arc Welding (GMAW), Flux-Cored Arc Welding (FCAW), Shielded Metal Arc Welding (SMAW), and Gas Tungsten Arc Welding (GTAW). Flat welding positions and basic joints will be practiced. Pipe and tube welding
3. Classification of Underwater Welding Underwater welding may be divided into two main types: a) Wet welding b) Dry welding Fig. 3.1 Classification of underwater welding 3.1 Wet welding 3.1.1. Wet welding with coated electrode Wet welding is performed at ambient pressure with the welder-diver in the water and no physical barrier
Ratio 104 121 143 165 195 231 273 319 377 473 559 649 731 841 1003 1247 1479 1849 2065 2537 3045 3481 4437 5133 6177 7569 50 Hz 60 Hz 13.9 12.0 10.1 8.79 7.44 6.28 5.31 4.55 3.85 3.07 2.59 2.23 1.98 1.72 1.45 1.16 0.98 0.754 0.702 0.572 0.476 0.417 0.327 0.282 0.235 0.192
