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Solid Projections

Solid Projections. (Solid State Welds). Solid Projections. Learning Activities View Slides; Read Notes, Listen to lecture Do on-line workbook. Lesson Objectives When you finish this lesson you will understand: Solid State Weld as applied to projections and studs

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Solid Projections

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  1. Solid Projections (Solid State Welds)

  2. Solid Projections • Learning Activities • View Slides; • Read Notes, • Listen to lecture • Do on-line workbook • Lesson Objectives • When you finish this lesson you will understand: • Solid State Weld as applied to projections and studs • Applications of Solid Projection Welds Keywords Solid Projection Weld, Solid State Weld, Swelling

  3. Resistance welder Manufacturers Association Bulletin # 35

  4. Resistance welder Manufacturers Association Bulletin # 35

  5. Heat Flows Into Cold Plate Thicker Plate = More Heat Loss Current Flow Heats Pipe Resistance welder Manufacturers Association Bulletin # 35

  6. Current Flow in the Solid Projection Current Density Less in Thicker Sheet Resistance welder Manufacturers Association Bulletin # 35

  7. Progression of Projection Collapse for a Simple Angled Projection

  8. Short Weld Time Low Weld Force Proper Weld Conditions Note Swelling of OD Slight Swelling of ID Excessive Weld Time Excessive Weld Force Proper Restricted Width Weld No Swelling of OD Resistance welder Manufacturers Association Bulletin # 35

  9. Photomicrographs Of Full Width Solid Projection Welds Resistance welder Manufacturers Association Bulletin # 35

  10. Photomicrographs Of Restricted Width Solid Projection Welds Resistance welder Manufacturers Association Bulletin # 35

  11. Parameters The Welding Parameters appear to be more dependent on Sheet Thickness than on Pipe Thickness Resistance welder Manufacturers Association Bulletin # 35

  12. Excessive Swelling Weld Force Acceptable Swelling There is a parameter limit which exceeded results in excessive pipe swelling Resistance welder Manufacturers Association Bulletin # 35

  13. Progression of Projection Collapse for a Beveled Annular Projection

  14. Typical Screw & Stud Parts for Projection Welding [Reference: Resistance Welding Manual, p.3-6, RWMA]

  15. Correct & Incorrect Location of Annular Projection Correct Projection Incorrect Projection [Reference: Resistance Welding Manual, p.3-5, RWMA]

  16. Application for Welding Studs or Bushing into Metal Opening Start of Welding Finish of Welding Electrode Electrode Weld Electrode Electrode [Reference: Resistance Welding Manual, p.3-5, RWMA]

  17. Application of Annular Projections Weld (a) (b) (c) (d) Threaded Boss Shoulder Stud Weld Tight Joint Relief for Upset Metal to Fill in [Reference: Welding Handbook, Volume 2, p.564, AWS]

  18. Typical Projection Weld Fasteners Weld Bolts Weld Pins Weld Nuts and Pads [Reference: Resistance Welding Manual, p.3-6, RWMA]

  19. Illustrating Use of Insulated Locating Pin for Welding Nut Insulated Steel Pin with Shoulder Electrode Weld Electrode Electrode Electrode [Reference: Resistance Welding Manual, p.3-7, RWMA]

  20. Recessed Electrode for Locating Nut for Welding Electrode Electrode Electrode Electrode Weld Weld Nut [Reference: Welding Handbook, Volume 2, p.567, AWS]

  21. Two Methods to Provide Accurate Location for Projection Welding Bolts to Sheet Insulation Bolt Retainer Projection Weld Bolt Projection Weld Bolt Flat Spring Sheet Metal Insulation Drill Hole in Electrode to Clear Threads [Reference: Resistance Welding Manual, p.3-8, RWMA]

  22. Solich, T “Improving Projection Welding Results” Practical Welding Today, Nov-Dec 1997

  23. Solich, T “Improving Projection Welding Results” Practical Welding Today, Nov-Dec 1997

  24. Ideal Microstructure for a Solid Projection Weld

  25. Effect of too Little Upset on Solid Projection Weld

  26. Effect of Excessive Upset on a Solid Projection Weld

  27. Excessive Weld Related Cracking

  28. Crack Propagation in a Solid Projection Weld

  29. Effects of Weld Time and Projection Shape Tube Pronounced Bulge Slight Bulge Notch Notch Sheet Before Welding After Welding Before Welding After Welding (a) Short Weld Time Full-Width Projection (b) Correct Weld Time Full-Width Projection [Reference: Metals Handbook Volume IV - Welding, Brazing and Soldering, ASM, p.503-524]

  30. Effects of Weld Time and Projection Shape (CONT.) Extensive Bulge Notch Notch Before Welding After Welding Before Welding After Welding (c) Excessive Weld Time Full-Width Projection (d) Correct Weld Time Reduced-Width Projection [Reference: Metals Handbook Volume IV - Welding, Brazing and Soldering, ASM, p.503-524]

  31. Troubleshooting Guide • Flashing of projections or “spitting of molten metal • Increase Pressure • Shorten Weld time • Increase squeeze time • Reduce heat • Check for dirty or scaly material • Check insulation in locating fixture • Burning, discoloration • Increase pressure • Shorten weld time • Add hold time • Reduce heat • Poor, weak or missing welds • Increase welder force • Increase welder KVA capacity • Increase weld time • Increase heat • Reduce electrode pressure Solich, T “Improving Projection Welding Results” Practical Welding Today, Nov-Dec 1997

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