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AWS Cl .1M E 1.I :2000



An American National Standard



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Key Words-



Resistance weld, spot weld, seam weld, flash weld, electrode force, weld current, weld strength, projection weld, lap joint, upset weld



AWS Cl .1M/C1.1:2000 An American National Standard Approved by American National Standards Institute January 31,2000



Recommended Practices



for Resistance Welding Supersedes AWS Cl.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 resistance welding equipment to produce resistance welded production parts. While the recommendations included are not expected to be final procedures for every production part or every welding machine, they serve as starting points from which a user can establish acceptable welding machinesettings for specific production welding applications. In some cases, recommended machine data is not available. In these instances, some description of the process is given to assist the readerin determining if the process might be suitable for application.



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Statement on Useof AWS American National Standards All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute. When AWS standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry the full legal authority of the statute. In such cases, 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 regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by agreement between the contracting parties. International Standard Book Number: 0-87171-601-0 American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126 O 2000 by American Welding Society. Allrights reserved Printed in the United States of America



AWS American National Standards are developed through a consensus standards development processthat brings together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracyof any information or the soundness of any judgments contained in its standards. AWS disclaims liability for any injury to personsor to property, or other damages of any nature whatsoever, whether SFcial, indirect, consequentialor compensatory, directlyor indirectly resulting from the publication, use of, or reliance on this standard. AWS also makes no guarantyor warranty as to the accuracy or completeness of any information published herein. In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on behalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using these documents should rely on his or her own independent judgmentor, as appropriate, seek the advice of a competent professional in determining the exerciseof reasonable care in any given circumstances.



This standardmay be superseded by the issuance of new editions. Users shouldensure that they have the latest edition. Publication of this standard does not authorize infringement of any patent. AWS disclaims liability for the infringement of any patent resulting from the useor reliance on this standard. Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so. Official interpretationsof any of the technical requirements of this standardmay be obtained by sending a request, in writing, to the Managing Director Technical Services, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126 (see Annex A). With regard to technical inquiries made concerningAWS standards, oral opinions on AWS standards may be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nordo these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation. This standard is subject to revision at any time by the AWS C1 Committee on Resistance Welding. It must be reviewed every 5 years and if not revised, it must be either reapproved or withdrawn. Comments (recommendations,additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should beaddressed to AWS Headquarters. Such comments will receive careful consideration by the AWS Cl Committee onResistance Welding and the author of the comments will be informed of the Committee’s responseto the comments. Guests are invited to attend all meetingsof the AWS C1 Committee on Resistance Welding to express their comments verbally. Proceduresfor appeal of an adverse decision concerningall such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.



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Personnel F! G. Harris, Chair W. H. Brafford, 1st Vice Chair B. J. Bastian, 2nd Vice Chair T. R. Potter; Secretary J . C. Bohr R. K. Cohen S. A. D’Ange10 **D.E. Destefan P Dent *R. J. Gasser J. M. Cerken *F! Howe R. N! Jud M. Kimchi J. W Lee *D. L. Olson J. F! Osborne *M. Prager W E Qualls W 7: Shieh



Centerline Welding, Limited CMW, Incorporated Benmar Associates American WeldingSociety General Motors Corporation WeldComputer Corporation Mercury Aircraft, Incorporated High Current Technologies, Incorporated Grumman Aircraft Systems Consultant Consultant Bethlehem Steel Corporation DaimlerChrysler Corporation Edison Welding Institute AlliedSigna1 Aerospace Colorado School of Mines Ford Motor Company Welding Research Council Valiant International Lockheed Martin Corporation



*Advisor



**Correspondence



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AWS C l Committee on Resistance Welding



Foreword (This Foreword is not a part of AWS Cl.lM/Cl.1:2000, Recommended Practices for Resistance Welding,but is included for information purposes only.)



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by the AWS Committee on Resistance The data contained in these Recommended Practices have been compiled Welding, by reviewing the data in the previous documents, by canvassing users of the resistance welding processes and correlating the data thus obtained. The resulting welding schedulesshown in the tables were circulated for comments and, in addition, some tests were conducted to ascertain that welds of the specified strengths could be obtained. The present edition of Recommended Practices representsan updated combination and extensionof data presented in the previous edition of AWS Cl.l-66, Recommended Practices for Resistance Welding;AWS C1.2-53, Recommended Practices for Spot Welding Aluminum and Aluminum Alloys; and AWS C1.3-70, Recommended Practices for Resistance Welding Coated Low Carbon Steels.Practices for new materials have been added and practices for materials which are not currently resistance welded in commercial production have been deleted. The new materials include high-strength low-alloy steels, both coated and uncoated. AWS (3.2-53 included data for electromagnetic and electrostatic stored energy machines. Since these types of machines are rarely used anymore, having been replacedby more flexible direct energy machines, these data have also been deleted. The AWS Committee on Resistance Welding has prepared these Recommended Practices in the hope that they will serve as an incentive for industry to develop methods and procedures improving upon the practice presented herein, which will permit the raising of quality and performance standards. If this is achieved, the Committee will have been amply repaid for the time and effort it has devoted to this work. Comments and suggestions for the improvement of this standard are welcome. They should besent to the Secretary, Committee on Resistance Welding, American Welding Society,550 N.W. Laleune Road, Miami, FL 33126.



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STD-AWS C L = L M / C L * L - E N G L 2000



0784265 0 5 1 3 b 5 1 215



Table of Contents Page No.



...



Personnel .................................................................................................................................................................... 111 Foreword ...................................................................................................................................................................... iv List of Tables............................................................................................................................................................... vi¿ ... List of Figures ............................................................................................................................................................ V l l l 1. Scope .....................................................................................................................................................................



1



2. Referenced Documents ......................................................................................................................................... 1 2.1 SafetyReferencess ...................................................................................................................................... 2 3. Nonstandard Terms and Definitions...................................................................................................................... 2 4 . Resistance Spot and Seam Welding ...................................................................................................................... 4.1 UncoatedCarbonandLow-Alloy Steels .................................................................................................... 4.2 Coated Carbon and Low-Alloy Steels ........................................................................................................ 4.3 Aluminum Alloys ..................................................................................................................................... 4.4 Stainless Steels, Nickel, Nickel-Base Alloys, and Cobalt-Base Alloys ................................................... 4.5Copperand Copper Alloys ....................................................................................................................... 4.6 Titanium and Titanium Alloys.................................................................................................................. 4.7 Welding Data Comments and Discussions Applicable to Various Metals ............................................... 4.8Weld Discrepancies and Causes ............................................................................................................... 4.9Weld Quality and Mechanical Property Tests ..........................................................................................



14 21 23 23 26 42 44



5 . Projection Welding .............................................................................................................................................. 5.1 Introduction .............................................................................................................................................. 5.2 EmbossedProjectionWelding .................................................................................................................. 5.3 SolidProjectionWelding .......................................................................................................................... 5.4Multiple Projection Welding .................................................................................................................... 5.5 Weld Quality and Mechanical Property Tests ..........................................................................................



63 63 63 67 67 67



6. Flash Welding...................................................................................................................................................... 6.1 Introduction .............................................................................................................................................. 6.2 Equipment................................................................................................................................................. 6.3 WeldingVariables ..................................................................................................................................... 6.4 WeldingVariableMeasurements .............................................................................................................. 6.5 Classificationof Steels for Flash Welding ............................................................................................... 6.6 Joint Preparation and Cleaning................................................................................................................. 6.7Welding Schedules ................................................................................................................................... 6.8 Weld Discrepancies and Causes ............................................................................................................... 6.9 Weld QualityandMechanicalPropertyTests ..........................................................................................



67 67 72 72 81 81 81 83 83 83



7. Upset Welding..................................................................................................................................................... 7.1 Introduction .............................................................................................................................................. 7.2 Equipment ................................................................................................................................................. 7.3 WeldingVariables ..................................................................................................................................... 7.4 Joint Preparation and Cleaning................................................................................................................. 7.5Welding Parameters .................................................................................................................................. 7.6 Weld Quality and Mechanical Property Tests ..........................................................................................



86 86 86 86 86 86 86



8.



2 2 6



Weld Bonding ...................................................................................................................................................... 87 8.1 Introduction .............................................................................................................................................. 87 8.2 Aluminum Alloys ..................................................................................................................................... 87



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Page No OtherMetals ............................................................................................................................................. WeldBonding Quality and MechanicalPropertyTests ............................................................................



89 90



9. Equipment Monitoring and Maintenance............................................................................................................



90



8.3 8.4



10. Safety and Health ................................................................................................................................................ 1O .1 General ..................................................................................................................................................... 10.2 Selection of Equipment ............................................................................................................................ 10.3 OperatorTraining ..................................................................................................................................... 10.4 Personal Protective Equipment ................................................................................................................. 10.5Installation ................................................................................................................................................ 10.6 Guarding ................................................................................................................................................... 10.7 Electrical ................................................................................................................................................... 10.8 Static Safety Devices ................................................................................................................................ 10.9 Ventilation................................................................................................................................................. 10.10 Maintenance ............................................................................................................................................. 1O .11 Fire Hazards.............................................................................................................................................. 1O .12 Noise ......................................................................................................................................................... 10.13 Lighting .................................................................................................................................................... 10.14 Signs ......................................................................................................................................................... 10.15 Hazardous Materials................................................................................................................................. Annex A-Cuidelines forPreparation of Technical Inquiriesfor AWS Technical Committees................................



94



94 94 94 94 94 94 95 96 96 96 97 97 97 97 97 103



AWS List of Documents on Resistance welding........................................................................................................ 105



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.



List of Tables .



1 2 3 4 5



6 7 8 9 10 11 12 13 14 15



16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32



33



Page No Spot Welding Parameters for Low-Carbon Steel ........................................................................................... 4 Pulsation Spot Welding Parameters for Low-Carbon Steel ........................................................................... 5 Seam Welding Parameters for Low-Carbon Steel.......................................................................................... 6 Spot Welding Parameters for HSLA Steel (ASTM A 715, Grades 50 and 60) Minimum Yield Strengths 345 to 415 MPa (50 to 60 ksi) ............................................................................. 7 Spot Welding Parameters for HSLA Steel (ASTM A 715, Grades 70 and 80) Minimum Yield Strengths 480 to 550 MPa (70 to 80 ksi) ............................................................................. 7 Spot Welding Parameters for HSLA Steel (ASTM A 568) Minimum Yield Point 380 MPa (55 ksi) .......... 8 Spot Weld Parameters for Low-Alloy and Medium-Carbon Steels ............................................................... 9 Electrode Materials for Resistance Welding................................................................................................ 10 Spot Welding Parameters for Galvanized Low-CarbonSteel ...................................................................... 11 Spot Welding Parameters for Galvannealed Low-Carbon Steel .................................................................. 12 Spot Welding Parameters for Galvanized HSLA Steel Minimum Yield Strengths 345, 415, 480, 550. and 620 MPa (50,60, 70, 80, and 90 ksi) .................................................................... 13 Seam Welding Parametersfor Galvanized Low-Carbon Steel..................................................................... 13 Basic Aluminum Alloy Groups.................................................................................................................... 14 Resistance Weldability Chart for Commonly Used Combinations of Aluminum Alloys (Based on Equal Thickness) ......................................................................................................................... 16 Recommended Spot Weld Spacing, Edge Distance. Overlap and Distance between Rows of Welds for Aluminum and Its Alloys ........................................................................................................ 18 Spot Welding Parameters for Aluminum Alloys on Standard Single-phase A-C Type Equipment............ 19 Spot Welding Parameters for Aluminum Alloys on Single-phase A-C Slope Control Type Machines......20 Spot Welding Parameters for Aluminum Alloys on Three-phase Rectifier Type Equipment ..................... 21 Spot Welding Parameters for Aluminum Alloys on Three-phase Frequency Converter Type Equipment (Single Impulse Welds)............................................................................................................. 22 Spot Welding Parametersfor Stainless Steels.............................................................................................. 24 Pulsation Spot Welding Parameters for Stainless Steels.............................................................................. 25 Seam Welding Parameters for Stainless Steels ............................................................................................ 26 Spot Welding Parameters for Annealed Nickel-Copper Alloyon Single-phase Equipment ....................... 27 Spot Welding Parameters for Annealed Nickel-Copper Alloy onThree-phase Frequency Converter Machines ..................................................................................................................................... 28 Seam Welding Parameters for Annealed Nickel-Copper Alloyon Single-phase Equipment ..................... 39 Seam Welding Parameters for Annealed Nickel-Copper Alloy on Three-phase Frequency Converter Machines..................................................................................................................................... 30 Spot Welding Parameters for Annealed Nickel-Chromium Alloy600 on Single-phase Equipment ..........31 Spot Welding Parameters for Annealed Nickel-Chromium Alloy X750on Single-phase Equipment .......32 Spot Welding Parameters for Annealed Nickel-Chromium Alloy X750on Three-phase Frequency ConverterMachines.................................................................................................................... 33 Spot Welding Parameters for Annealed Nickel-Chromium Alloy X750on Three-phase Dry Disc Rectifier Machines............................................................................................................................... 34 Seam Welding Parameters for Annealed Nickel-Chromium Alloy X750 onSingle-phase Equipment ......35 Seam Welding Parameters for Annealed Nickel-Chromium Alloy X750 on Three-phase Frequency Converter Machines............................................................................................... 36 Roll Spot Welding Parameters for Annealed Nickel-Chromium Alloy X750 on Three-phase Dry Disc Rectifier Machines................................................................................................... 37



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Table



Page No. 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53



54 55 56 57 58 59



Spot Welding Parameters for Annealed Nickel on Single-phase Equipment ..............................................



Spot Welding Parameters for Nickel-Iron-Chromium AlloyX ...................................................................



Seam Welding Parameters for Nickel-Iron-Chromium Alloy X .................................................................. Spot Welding Parametersfor Cobalt-Chromium-Nickel Alloy ................................................................... Spot Welding Parameters for Various Copper Alloys .................................................................................. Spot Welding Parametersfor Titanium Alloy 6%A1-4%V.......................................................................... Variation of Current Density and Unit Force Due to Lack of Electrode Tip Maintenance.......................... Spot Welding Parameters for Various Thickness Combinations and Arrangements of Uncoated and Coated-Carbon and Low-Alloy Steels .................................................................................. Projection and DieGeometries for Welding a Range of Heavy-Gauge Steels ............................................ Process Requirements for Projection Weldinga Range of Heavy-Gauge Steels......................................... Punch Design Datafor Low-Carbon Steel Projections ................................................................................ Die Button Design Data for Low-Carbon Steel Projections ........................................................................ Punch and Die Design Datafor Forming Projections on Stainless Steels ................................................... Projection Welding Parametersfor Low-Carbon Steel ................................................................................ Projection Welding Parameters for Galvanized Low-Carbon Steel ............................................................. Projection Welding Parameters forStainless Steels..................................................................................... Projection Designs and Process Requirements for Annular Projection WeldingSome Representative Light-Gauge Steels .............................................................................................................. Projection Welding Design Datafor Stainless Steels .................................................................................. Projections for Low-Carbon Steel .....i.......................................................................................................... Process Requirements for Cross-Wire Weldinga Range of Thicknesses of Hot- and Cold-Drawn Steel Wires ................................................................................................................................................... Data for Flash Welding of Tubing and Flat Sheets ...................................................................................... Data for Flash Welding of Solid Round, Hex, Square, and Rectangular Bars ............................................. Weld-Bonding Surface Preparation for Aluminum Alloys by Low-Voltage Anodizing ............................. Comparison between Resistance Spot Welding and Weld-Bonding ofAluminum Alloys ......................... Typical Spot Welding Parameters for 1.6 mm (0.063 in.) Thick 7075-T6 Aluminum Treated with a Low-Voltage Anodizing Process ....................................................................................................... Commonly Used Metric Conversions Inch-Millimeter Conversion ............................................................



...



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38 39 39 39 40 40 41 43 65 66 68 69 70 71



71 71 72 73 74 76 84 85 88 89 89 98



List of Figures



.



Figure 1



2 3 4 5 6 7 8 9 10 11 12



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13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28



29 30 31 32 33 34 35 36



Page No Standard RWMA Nose or Tip Geometries of Spot Welding Electrodes ..................................................... Coring in Nickel Alloy 718 (UNS N07718) Resistance Seam Weld. 200X ................................................ Peel Test....................................................................................................................................................... Peel Test Specimens ..................................................................................................................................... Measurement of a Weld Button Resulting from the Peel Test..................................................................... Bend Test Specimen ..................................................................................................................................... Spot Weld Chisel Test .................................................................................................................................. Tension-Shear Test Specimen ...................................................................................................................... Twisting Angle y at Fracture in Tension Shear Test ..................................................................................... Cross-Tension Test Specimens..................................................................................................................... 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).................................................................................................................... Test Specimen and Typical Equipment for Torsion-Shear Test................................................................... Drop-Impact Test Specimen......................................................................................................................... Drop-Impact Test Machine .......................................................................................................................... Test Fixture for Shear-Impact Loading Test ................................................................................................ Test Fixture forTension-Impact Loading Test............................................................................................. Fatigue Testing Machine.............................................................................................................................. Pillow Test for Seam Welds......................................................................................................................... Typical Stack-up Configuration for Embossed Projection Welding ofSheet .............................................. Typical Configuration for Solid Projection Welding................................................................................... Diagram Defining How Set-Down is Estimated on Cross-Wire Welds ....................................................... Characteristics of Projection Collapse during Annular Projection Welding with Different Base Projection Widths......................................................................................................................................... Chart of Flash WeldingDefinitions ............................................................................................................. Chart of Flash Welding Definitions............................................................................................................. Flash Welding of Tubing and Flat Sheets .................................................................................................... Flash Welding of Solid Round, Hex, Square, and Rectangular Bars ........................................................... Comparison of Tensile-Shear Strengths of Uncured and Cured (Single Spot) Weld-Bonded Joints of 7075-T6 Aluminum Alloy ....................................................................................................................... Comparison of Fatigue Test Results of Weld-Bonded and Adhesive-Bonded Joints of 7075-T6 Aluminum Alloy .......................................................................................................................................... Fatigue Test Specimenof Weld-Bonded and Adhesive-BondedJoints ....................................................... Form for Resistance Welding Data Sheetfor Spot and Projection Welding................................................ Form for Resistance Welding Data Sheet for Seam Welding .................................................................... Form for Resistance Welding Data Sheetfor Flash or Upset Welding......................................................



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14 21 46 47 48 49 50 50 51 52 53 54 55 56 56 57 59 60 61 61 62 62 64 64 77 78 79 80 82 82 90



91 92 99



100 101



STDOAWS C L * L M / C L * L - E N G L 2000 D 078Y2b5 0 5 L 3 b 5 b 8T7 AWS Cl .1 M/C1.1:2000 --``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



Recommended Practices for Resistance Welding



1. Scope



Documents 2. Referenced



I t is the intent of this publication to present current concepts and practices for resistance welding (and related processes) of ferrous and nonferrous metals including coated and dissimilar metals. Where practical, welding schedules are included. In other instances where schedules 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. It is 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 schedules 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, it is imperative that reference be made to the appropriate text. Failure to refer to the text may result in misinterpretation of the data in the tables. The text has been kept as brief as possible and all extraneous comments have been omitted. For more detailed information on the fundamentals of the resistance welding processes and the types of equipment utilized for the different processes, consult the current AWS Welding Handbook. This standard makes use of both the InternationalSystem of Units (SI) and U.S. Customary Units. The measurements 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. I M:2000 USeS units. Thestandarddesignation c1.1:2000 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.



(1) AWS Cl .4M/C1.4:2000, Specification for Resistance Welding of Carbon and Low-Alloy Steels (2) AWS A2.4, Standard Symbols for Welding, Brazing and Nondestructive Testing (3) AWS A3.0, Standard Welding Terms and Definitions (4) AWS D8.6, Standard for Automotive Resistance Spot Welding Electrodes (5) AWS D8.7, Recommended Practices for Automotive Weld Quality-Resistance Spot Welding (6) AWSD8.9, Recommended Practices for Test Methods for Evaluating the Resistance Spot Welding Behavior ofAutomotive Sheet Steels (7)AWS Welding Handbook, Volume 2, Eighth Edition, Chapter 17, “Spot, Seam, and Projection Welding,” American Welding Society (8) AWS PARW, The Professional’sAdvisor on Resistance Welding, American Welding Society (9) Welding Aluminum: Theory andPractice, Chapter 13 “Resistance Welding,” The Aluminum Association,’ Washington DC, 1991 (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, 4 t h Edition, Resistance Welder Manufacturers’ Association, 19894



1 . Available from AA, 900 19th Street, NW, Washington, DC 2ooo6. 2. Available from ~~~~i~~~ Societyfor Testingand Materials, 100 Harbor W. Conshohocken, PA, 19428. 3. Available from ASM lntcrnational,Materials Park, OH 44073-0002. 4. Available from RWMA, 1900 Arch Street, Philadelphia, PA 19103-1498.



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AWS Cl .I M/C1.1:2000



(12) Society of Manufacturing Engineers, Tooland Manufacturing Engineers Handbook, Volume 4, Fourth Edition, 1987.s



bake-hardenable steel. Low-carbon steel having the capability of being strengthened during a subsequent heat treatingoperation, usually a paint baking process.



2.1 Safety References (1) ANSI 249.1, Safety in Welding, Cutting, andAllied Processes, published by AWS ( 2 ) Effects on Welding andHealth, published by AWS (3) Safety and Health Fact Sheets, published by AWS (4) Occupational Safety andHealth Administration (OSHA), Code of Federal Regulations, Title 29 Labor, Chapter XVII,Part 1910, “Occupational Safetyand Health Standards”6 ( 5 ) ANSI 2 4 1 , Personal Protection-Protective Footwear7 (6) ANSI 287.1, Practice for Occupational and Educational Eye and FaceProtection (7) ANSI 288.2, Respiratory Protection (8) ANSI 289.1, Protective Headwear for Industrial Workers (9) ASME 815.1, SafetyStandard for Mechanical Power Transmission ApparatusX (10) ANSI 2535.5, Accident Prevention Tags (1 1) National Institute for Occupational Safety and Health, NIOSH Criteria Document, Recommended Standard for Welding, Brazing, and ThermalCutting, 1 98g9 (12) General Motors Corporation, PED 960, Personnel Safety Standardsfor Assembly Plant Equipment and Tools, May, 1977 (1 3) NationalFireProtectionAssociation, National Electrical Codeio (14) NationalFire Protection Association, Standard 5 1 B, Cutting and WeldingProcesses



dent-resistant steel. A general term for low-carbon steels having higher resistance to plastic deformation than standard cold-rolled, low yield strength, lowcarbon steels. It encompasses high-strength low-alloy (HSLA), bake-hardenable and dual-phase steels.



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 with greater tensile and yield strengths than low-strength low-carbon steel. penetrator. A nonmetallic oxide inclusion in a flash weld. phase shift control. A control commonly used in resistance welding machines to adjust initiating the point allowing onlya portion or percentageof each alternating current half cycle to pass to the welding transformer. mushrooming. The deformation of an electrode, initiated at the contact surface as a result of the various actions occurring during welding. weld discrepancy.A weld condition that deviates from the applicable standard, specification, or engineering drawing. weld lobe. The current, time, and force ranges which provide acceptable welds.



Most of the following terms are applicable only to resistance welding. Flash welding variables are defined in 6.3 For additional welding terms, see AWS A3.0, Standard Welding Terms andDefinitions.



4. Resistance Spot and Seam Welding 4.1 Uncoated Carbon and Low-AlloySteels 4.1.1 Introduction



5. Available from SME, One SME Drive, PO Box 930, Dear-



born, MI 48121. 6. Available from Superintendent of Documents, U.S. Government Printing Office, Washington,DC 20402. 7. Available from American National Standards Institute, 11 West 42nd Strect, 13th Floor, Ncw York, NY 10036-8002. 8. Available from ASME International,Three Park Avenue, NewYork, NY 10016-5990. 9. AvailablefromNIOSH, 4676 ColumbiaParkway,Cincinnati, OH 45226. 10. Available from National Fire Protection Association, One Batterymarch, Quincy,PA 02269.



4.1.1.1Low-CarbonSteels. Low-carbon steels contain less than0.20% carbon and less than0.50% manganese, with the remaining alloying elements totaling less than 1%. The maximum hardness attainable in carbon and low-alloy steels is dependent almost exclusively on the carbon content. In addition to this effect on maximum hardness, carbon has a relatively strong influence in increasing the depth or ease of hardening. Manganese also combines with sulfur and reduces the tendency toward hot-cracking. Hot-cracking results from the low 2



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3. Nonstandard Terms and Definitions



governing metal thickness. The thickness of the sheet (usually the thinnestouter sheet) on which the required nugget size and depth of fusion in a resistance weld are based.



STD=AWS CL*LM/CL.L-ENGL 2000 m . 0 7 8 9 2 b 5 0 5 L 3 b 5 8 b7T AWS C1.lM/Cl.l:2000



4.1.2SurfaceConditions. Priorto welding, the workpiece surface should be free of contaminants which might adversely affect the weld quality.Surface contaminants and organic coatings can adversely affect the chemical composition of the weld. Uncoated steel is typically classified as either hotrolled 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-rolled and hot-rolled, pickled and oiled steel sheets do not exhibit mill scale because the mill scale is removed during the material processing. Low-carbon and HSLA steel sheets are typically supplied in both the hot-rolled, pickled and oiled, and cold-rolled conditions. Materials in these conditions are weldable as long as surface contaminants are minimized.



4.1.1.2Medium-Carbonand Alloy Steels. Medium-carbon steels contain 0.20-0.55% carbon with the remaining alloying elements totaling less than 1 .O%. Steels are considered to be alloy steels when the maximum of the range given for the content of alloying elements 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 elements is specified or required within the limits of the recognized fieldof constructional alloy steels: aluminum, and chromium up to 9%; cobalt, niobium, molybdenum, nickel, titanium, tungsten, vanadium, zirconium,or any other alloying element added to obtain a desired alloying effect. Highercarbonlevelsrepresenthigherhardenability, and care is required when welding these steels. For this reason, medium-carbon steels have an increased tendency toward embrittlement than do low-carbonsteels. Mediumcarbon and alloy steels frequently require preheating prior to, and tempering treatments after, welding. These steels may be heat treated on welding equipment with the necessary controls, or heat treated as a separate operation.



4.13 Welding Parameters. The data shown in Tables 1 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 production 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 carbon and low-alloy steels as well as other metals are presented separately in 4.7. 4.13.1 Electrodes. Resistance Welder Manufacturers’ Association (RWMA) Group A, Class 2 electrodes (see Table8) are generally recommended for these steels because this group of electrodes maintains relatively high strengths at elevated temperatures. They will have reasonable life when correctly used to weld these steels. These electrodes are copper-chromium or copperchromium-zirconium, and exhibit higher strengths and correspondingly reduced electrical conductivities than Class 1 copper electrodes.



4.1.13 High-CarbonSteels. High-carbon steels contain more than 0.55% and less than 1.50% carbon. These steels have high hardenability and are not easily resistance welded without weld cracking. Special procedures must be used when resistance welding these steels. 3 Copyright American Welding Society Provided by IHS under license with AWS



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4.1.1.4 High-StrengthLow-Alloy (HSL4) Steels. High-strength, low-alloy steels obtain their strength and other mechanical properties through the addition of alloying elements, or through thermal processing, or both. Alloying elements may include niobium, vanadium, nitrogen, phosphorus, or rare earth additions. Thermal processes which impart strength include controlled cooling, recovery annealing, and controlled annealing. Yield strength levels range from 241 MPa (35 ksi) to over 690 MPa (100 ksi). When welding HSLA steels, welding schedules may include preweld heat conditioning, or postweld heat treatment to improve the microstructure of the weld nugget, HAZ, or both.



strength of the steel at high temperatures. The steel cannot accommodate the stresses which develop during cooling, and cracks form i n the weld metal or i n the heataffected zone (HAZ). Low-carbon steels have typical bulk electrical resistivities (¡.e., the specific electrical resistivity of a given volume of metal) of 10-20 yS2-cm (4-8 @-in.), and have large plastic ranges. Both of these characteristics make low-carbon steel quite weldable using resistance welding processes. However, low-carbon steels with carbon levels greater than 0.13% may be susceptible to hardening; therefore, the rapid cooling rates of resistance spot and seam welding are of concern for steels containing these levels of carbon. In this carbon range, precautions 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 interstitial-free (I-F) steels. Dent-resistant materials are defined 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 (columbium) and titanium additions to improve formability. Welding of these materials is similar to most low-carbon steels and similar welding schedules can be used.



~



=



STD-AWS CL.LM/CL-L-ENGL 2000



078q2b5 0513b59 50b



AWS Cl.lM/C1.1:2000



Table 1 Spot Welding Parameters for Low-CarbonSteel5



Metal2 Thickness mm (in.)



Ele~trode’.~ Net Face Electrode Diameter



mm (in.)



Force kN (lb)



Welding Cycles



Amps



7



8 500 9 500 10 500



0.51 (0.020) 4.76 (0.187) 1.78 (400)



0.64 (0.025) 0.76 (0.030) 0.89 (0.035) 1 .O2 (0.040) 1.14 (0.045) 1.27 (0.050) 1.40 (0.055) 1.52 (0.060) 1.78 (0.070) 2.03 (0.080) 2.29 (0.090) 2.67 (0.105) 3.05 (O. 120)



4.76 (0.187) 6.35 (0.250) 6.35 (0.250) 6.35 (0.250) 6.35 (0.250) 7.94 (0.313) 7.94 (0.313) 7.94 (0.313) 7.94 (0.313) 7.94 (0.313) 9.52 (0.375) 9.52 (0.375) 9.52 (0.375)



Contact



Minimum4 Weld



Minimum Shear



Overlap mm (in.)



Spacing mm (in.)



Strength’ kN (Ib)



11.2 (0.44) 11.Y (0.47) 13.0 (0.5 1) 13.5 (0.53) 14.2 (0.56) 15.0 (0.59) 15.5 (0.61) 16.0 (0.63) 16.5 (0.65) 17.3 (0.68) 18.3 (0.72) 19.8 (0.78) 21.3 (0.84) 25.9 (1.02)



9.5 (0.37) 12.7 (0.50) 15.9 (0.63) 19.0 (0.75) 21.6 (0.85) 23.9 (0.94) 25.4 (1 .OO) 27.0 (1 .06) 28.6 (1.13) 56.5 (1.25) 36.5 (1.44) 39.7 (1.56) 42.9 (1.69) 46.0 (1.81)



Minimum



Weldh Current Time (Approx.1



2.00 (450) 2.22 (500) 2.67 (600) 3.11 (700) 3.34 (750) 3.56 (800) 4.00 (900) 4.45 (1 000) 5.34 (1 200) 6.23 (1400) 7.72 (1 600) 8.01 (1800) 9.34 (2100)



8



9 9 10 11



12 13 14 16 18 20 23



26



11 500 12 500 13 O00 13 500 14 O 0 0 15 O00 16 O00 17 O00 18 O00 1 9 500 21 O00



Nugget Diameter mm (in.) ’



Minimum



Satisfactory



Setup



4.57 (0.180) 1.42 (320) 3.1 (0.12) 4.57 (0.180) 2.00 (450) 3.1 (0.12) 6.35 (0.250) 2.45 (550) 3.6 (0.14) 3.34 (750) 4.1 (0.16) 6.35 (0.250) 6.35 (0.250) 4.6 (0.18) 4.11 (920) 5.12 (1150) 4.8 (0.19) 6.35 (0.250) 6.01 (1350) 5.1 (0.20) 7.94 (0.313) 7.12 (1600) 5.3 (0.21) 7.94 (0.313) 7.94(1850) (0.313) 5.8 (0.23) 8.23 7.94 (2300) (0.313) 6.4 (0.25) 10.23 12.01 (2700) 6.6 (0.26) 7.94 (0.313) 9.52(3450) (0.375) 6.9 (0.27) 15.35 9.52 (4150) (0.375) 7.1 (0.28) 18.46 9.52 (5000) (0.375) 7.6 (0.30) 22.24



General Notes: 1. Shapes that can be used are: E = Truncated cone (45-degbevel) A = Pointed B =Domed F = Radius tip Also see Figure 1. 2. For intermediate thicknesses, force, weld time, andcurrent may be interpolated. 3. Electrode material: RWMA Class 2. 4. Minimum weld spacing is measured from centerline to centerline. 5. The data within this table was supplied by committee members and representsan average of typical parameters used in industry. 6. Based on single-phase a-c60 Hz equipment. 7. Based on 200 MPa (30 ksi) yield strength material.



--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



4.13.2 Net Electrode Force. High-strength (HS) steels typically require higher electrode forces than lowstrength, low-carbon steels. The higher forces are necessary to overcome the higher faying surface contact resistance 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 electrode 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. Insulation should be used to prevent current shunting through the clamps. HS steels, because of their higher yield strengths, may experience excessive spring-back after completion of the weld if the adjacent clamping force is not adequate. Excessive spring-back may result in weld fracture. However, electrodes should not be used as clamping tools to overcome poor joint fit-up.



and low-alloy steels. Some HS steels require very short or no hold timein order to minimize embrittlement of the weld nugget. The hold time typical of low-strength, lowcarbon 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 interfacial fracture, or results in a partial button or cracks are found in the metal, the material is“hold time sensitive.”



4.13.4 Temper Time. Medium-carbon and some HS steels may require postweld heating in order to improve the mechanical properties of the weld. This may be obtained by applying a separate tempering current in the weld schedule. The weld should be cooled to a temperature below the critical temperature for martensite formation before the application of the tempering current. The



4.133 Hold Time. Typical hold time to solidify the weld nugget varies from 5-15 cycles for low-carbon 4 Copyright American Welding Society Provided by IHS under license with AWS



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U



o, h



.fi



“-JI”



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Table 3 Seam Welding Parameters for Low-Carbon Steel1$



*



I



elect rod^^.^ Width and Shape Minimum'



76 mm



Contact Overlap mm (in.)



(3 in.) RADIUS E



Thickness 01 the Thinnest Piece Metal mm (in.)



W mm (in.), min.



E mm (in.)t



0.25 (0.010) 0.53 (0.021) 0.79 (0.031) 1.02 (0.040) 1.27 (0.050) 1.57 (0.062) 1.Y8 (0.078) 2.38 (0.094) 2.77 (O. 109) 3.18 (0.125)



9.5 (0.37) 9.5 (0.37) 12.7 (0.50) 12.7 (0.50) 12.7 (0.50) 12.7 (0.50) 15.Y (0.63) 15.9 (0.63) 19.0 (0.75) 19.0 (0.75)



4.6 (O. 18) 4.8 (0.1 Y) 6.4 (0.25)



max.



7.9 (0.31) 7.9 (0.31) YS (0.37) 11.1 (0.44) (0.50)



Net Electrode Force kN (Ib)



On Time Cycles6



Off Time Cycles6



2 1.78 (400) 2 2.45 (550) 3 4.00 (900) 3 4.34 (980) 6.4 (0.25) 4 4.67 (1050) 4 5.34 (1200) 6 6.67 (1500) 7 7.56 (1700) 9 8.67 (1 950) 12.7 (0.50) 9.79 (2200) 12.7 11



1 2 2 3



3 4 5 6 6 7



Weld' Spced m/min (in./min) 2.0 (79) 1.9 (75) 1.8 (71) 1.7 (67) 1.7 (67) 1.6 (63) 1.4 (55) 1.3 (51) 1.2 (47) 1.1 (43)



"ILI"



B



Welds per meter



Current



(in.)



Amps



&&



8 O00 11 o00 13 O00 15 O 0 0 16 500 17 500 19 O00 20 o00 21 o00 22 o00



9.5 (0.37) 11.1 (0.44) 12.7 (0.50) 12.7 (0.50) 14.3 (0.56) 15.9 (0.63) 17.5 (0.69) 19.0 (0.75) 20.6 (0.81) 22.2 (0.87)



5W (15) 470 (12) 3Yo (10) 350 (Y) 310 (8) 280 (7) 240 (6) 220 (5.5) 200 (5) 180 (4.5)



General Notes: 1. Type of steel-SAE 1010. 2. Material should be free from scale, oxides, paint, grease, and oil. 3. For the electrodes with a radius face, the face width is the same as the electrode width. 4. Electrode material: R W M A Class 2. 5. For large assemblies, minimum contactingoverlap indicated should be increased by 30 percent. h. Based on single-phase a-c 60 Hz equipment. 7. Welding speeds noted do not give a leak-tight seam.



tempering current should not remelt the weld nugget nor reheat the weld above theaustenitizing temperature.



with the base metal may occur, which may alter corrosion protection, Coated steel may give off fumes while being welded. Care should betakento ensure proper ventilation to remove these fumes from the welding area. ventilation is



"



4.13S Weld Current' 'Ompared with lowstrength, 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 toproduce similar weldnuggetdiameters.



addressed in 10.9. 4.2.2 Qpes of Coating. The following is a list of various types of coatings used on steels along with some comments: (1) Zinc-Base. These coatings are normally applied either by hot-dipping or by electrolytic deposition. (a) Zinc (commonly referred to as galvanized or electrogalvanized). (b) Zinc-aluminum (Zn + 5 percent AI). (c) Zinc-nickel. (d) Chromium + chromium-oxide + zinc. (e) Zinc-iron. (2) Aluminum-Base. (a) Type 1 aluminum (AI with 5-10 percent silicon). (b) Type 2 aluminum (pure AI). (c) Aluminum-zinc (45 percent Zn + 1.5 percent Si).



4.2 Coated Carbonand Low-Alloy Steels



4.2.1 Introduction. Metallic or nonmetallic coatings are applied to sheet steels primarily to improve thecorrosion resistance of the steel during service. These coatings, however, present some weldability concerns. Coatings alter the contact resistance at the electrode-toworkpiece interface and faying surfaces. They generally require increased current, which may result in increased heating of the electrode. Coatings may cause rapid erosion of electrodes by wear, or by alloying with the electrode material. Electrode sticking due to thisalloying can result in pitting of the electrode tip and rapid electrode face erosion. In addition, some alloying of the coating 6 Copyright American Welding Society Provided by IHS under license with AWS



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Table 4 Spot Welding Parameters for HSLA Steel (ASTM A 715, Grades 50 and 60) Minimum Yield Strengths 345 to 415 MPa (50 to 60 ksi) Minimum Nugget Minimum Welding Contact Current Weld Time Overlap (Approx.) mm (in.) Cycles2 Amps



3lectr0del.~ Net Elcctrodc Face Diameter Force mm (in.) kN (lb)



Metalh Thickness mm (in.)



--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



0.51 (0.020) 0.61 (0.024) 0.76 (0.030) 0.91 (0.036) 1.O9 (0.043) 1.35 (0.053) 1.63 (0.064) 1.96 (0.077) 2.36 (0.093) 2.87 (O. 1 13) 3.48 (0.137)



4.6 (O. 18) 4.6 (O. 18) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 7.9 (0.31) 7.9 (0.31) 7.9 (0.31) 8.9 (0.35) 8.9 (0.35) 8.9 (0.35)



8 8



2.00 (450) 2.36 (530) 2.85 (640) 3.11 (700) 3.69 (830) 4.45 ( 1000) 5.34 (1200) 6.36 (1430) 7.70 (1 730) 9.34 (2100) l1.12(2500)



Y



10 11



13 21 38 51



1 1.2 (0.44) 5600 6 300 11.Y (0.47) 7 000 13.0 (0.5 1) 8 100 13.5 (0.53) 14.7 (0.58) 8 "O 15.7 (0.62) 10 o00 11 100 1716.8 (0.66) 18.0 (0.71) 12 100 13 300 20.1 28 (0.79) 14 500 20.3 (0.93) 15 700 29.7 (1.17)



Minimum Weld Spacing' mm (in.)



9.5 (0.37) 12.7 (0.50) 15.9 (0.63) 19.0 (0.75) 22.9 (0.90) 26.4 (I .04) 29.7(1.17) 35. I (1.38) 46.1 (13 3 ) 44.2 (1.74) 49.8 (1.96)



Minimum Shear Strength, kN (Ib)



Satisfactory Setup Diameter Diameter mm (in.) mm (in.)



2.1 1 (475) 2.36 (525) 3.43 (770) 4.83 (1085) 5.76 (1295) 7.16 (1610) 1 1 .O7 (2490) 14.37 (3230) 17.30 (3890) 22.86 (5140) 26.47 (5950)



4.57 (0.180) 4.57 (0.180) 6.35 (0.250) 6.35 (0.250) 6.35 (0.250) 7.92 (0.312) 7.92 (0.312) 7.92 (0.312) 8.89 (0.350) 8.89 (0.350) 6.4 (0.25) 6.4 (0.25) 8.89 (0.350)



3.1 (0.12) 3.1 (0.12) 3.1 (0.12) 4.6 (0.18) 4.6 (O. 18) 4.6 (0.18) 4.6 (0.18) 5.6 (0.22) 5.6 (0.22)



General Notes: 1. Shapes that ciln be used are: &Truncated cone (45-deg bevel) A-Pointed Also see Figure 1. 2. Data are based on single-phase a-c 60 Hz equipment. 3. Minimum weld spacing is measured from centerline to centerline. 4. Electrode material: RWMA Class 2. 5. Hold t i m e S e e 4.1.3.3. 6. For intermediate thicknesses, force and weld time may be interpolated.



Table 5 Spot Welding Parameters for HSLA Steel (ASTM A 2715, Grades70 and 80) Minimum Yield Strength485 to 550 MPa (70 to 80 ksi) Minimum Nugget Net Electrode'*4 Electrode Metal6 Face Thickness Force Diameter kN (Ib) mm (in.) mm (in.)



Welding Weld Current Time (Approx.) Amps Cycles2



2.00 (450) 4.6 (0.18) 2.36 (530) 4.6 (O. 18) 2.85 (640) 6.4(0.25) 3.11 (700) 6.4 (0.25) 3.69 (830) 4.45 (1000) 6.4 (0.25) 1.35 (0.053) 6.4 (0.25) 5.34 (1 200) 7.9 (0.31) 6.36 (1430) 7.9 (0.31) 7.70 (1730) 8.9 (0.35) 9.34 (2100) 8.9 (0.35) 11.12 (2500)



0.51 (0.020) 4.6 (0.18)



0.61 (0.024) 0.76 (0.030) 0.91 (0.036) 1.O9 (0.043) 1.63 (0.064) 1.Y6 (0.077) 2.36 (0.093) 2.87 (0.1 13) 3.48 (0.137)



8 8 9



10 11 13



17 21 28 38 51



5 500



6 500 7 O00 7 900 9 O00 9 900 10 700 1 1 800 12 500 13 400 14 300



Minimum Contact Overlap mm (in.)



Minimum Weld Spacing3 mm (in.)



1 1.2 (0.44) 9.5 (0.37) 1 1.9 (0.47) 12.7 (0.50)



13.0 (0.51) 13.5 (0.53) 14.7 (0.58) 15.7 (0.62) 16.8 (0.66) 18.0 (0.7I) 20.1 (0.79) 20.3 (0.93) 29.7(1.17)



15.9 (0.63) 19.0 (0.75) 22.9 (0.90) 26.4 (1.04) 29.7(1.17) 35.1 (1.38) 46.1 ( I .58) 44.2 (1.74) 49.8 ( 1 .96)



Minimum Shear Strength,



kN (Ib) 2.36 (525) 2.89 (650) 4.40 (990) 6.2 I (1 395) 7.4 I (1 665) 9 .2 1 (2070) 14.63 (3290) 18.37 (4130) 22.42 (5040) 1 29.36 (6600) 33.81 (7600)



Satisfactory Diameter mm (in.)



3.1 (0.12) 3.1 (0.12) 3.1 (0.12) 4.6 (0.18) 4.6 (0.18) 4.6 (O. 18) 4.6 (O. 18) 5.6 (0.22) 5.6(0.22) 6.4 (0.25) 6.4 (0.25)



setup Diameter mm (in.)



4.57 (O. 180) 4.57 (0. 180) 4.57 (O. 180) 6.35 (0.250) 6.35 (0.250) 6.35 (0.250) 6.35 (0.250) 7.92 (0.3 12) 7.92 (0.312) 8.89 (0.350) 8.80 (0.350)



General Notes: I . Shapes that cm be used are: E-Truncated cone (45-deg bevel) A-Pointed Also see Figure 1. 2. Data is based on sinele-ohase a-c 60 Hz eauioment. 3. Minimum weld spakng'is measured from centerline to centerline. 4. Electrode material: R W M A Class 2. 5. Hold t i m e S e e 4.1.3.3. 6 . For intermediate thicknesses, force and weld time may be interpolated. I



I



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Table 6 Spot Welding Parameters forHSIA Steel (ASTM A 568, Minimum Yield Point 380 MPa [55 ksi])



Metal Thickness mm (in.)



Electrode' Flat Face (Truncated Tip) mm (in.)



0.51 (0.020) 4.6 (0.18) 0.61 (0.024) 4.6 (O. 18) 0.76 (0.030) 6.4 (0.25) 0.9 1 (0.036) 6.4 (0.25) 1.O9 (0.043) 6.4 (0.25) 1.35 (0.053) 7.9 (0.31) 1.63 (0.064) 7.9 (0.31) 1.96 (0.077) 7.9 (0.31) 2.36 (0.093) 8.9 (0.35) 2.87 (O. 1 13) 8.9 (0.35) 3.48 (0.1 37) 8.9 (0.35)



Net Electrode Force kN (Ib) 2.00 (450) 2.36 (530) 2.85 (640) 3.11 (700) 3.69 (830) 4.45 (1000) 5.34 (1200) 6.36 (1 430) 7.70 (1 730) 9.34 (2100) 1.12(2500)



Minimum



Minimum3



Minimum



Weld* Time Cycles



Welding



Contact Overlap mm (in.)



Weld



Shear



Current Amps



Spacing mm (in.)



Strength kN (Ib)



8 8 9 10



5 500 6 100 6 YO0 7 700 8 700 10 O00 11 500 12 100 13 O00 14 200 15 600



11.2 (0.44) 11.9 (0.47) 13.0 (0.51) 13.5 (0.530 14.7 (0.58) 15.7 (0.62) 16.8 (0.66) 17.8 (0.70) 20.3 (0.80) 23.6 (0.93) 31.2 (1.25)



9.5 (0.37) 12.7 (0.50) 15.9 (0.63) 19.0 (0.75) 22.9 (0.90) 26.2 (1.03) 30.0 (1.18) 35.8 (1.37) 40.6 (1.60) 44.4 (1.75) 50.8 (2.00)



11



13 17 21



27 37 48



T



Nugget Diameter mm (in.)



Minimum Satisfactory



2.00 (450) 3.1 (0.12) 2.22 (500) 3.1 (0.12) 3.34 (750) 3.6 (0.14) 4.89 (1 100) 4.6 (0.18) 5.78 (1300) 4.8 (0.19) 6.78 (1 520) 5.3 (0.21) 11.56 (2600) 6.1 (0.24) 14.23 (3200) 6.6 (0.26) 16.90 (3800) 7.1 (0.28) 22.24 (5OOO) 7.8 (0.31) 27.80 (6250) 8.6 (0.34)



Setup 4.57 (0.180) 4.57 (0.180) 6.35 (0.250) 6.35 (0.250) 6.35 (0.250) 7.94 (0.313) 7.94 (0.313) 7.94 (0.313) 8.89 (0.350) 8.89 (0.350) 8.89 (0.350)



General Notes: 1. Electrode material: RWMA Class 2. 2. Based on single-phase a-c60 Hz equipment. 3. Minimum weld spacing is measured from centerline to centerline.



(5) Zinc-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 steel at the faying interface improves weldability. (6) Organic composite. These coatings are applied to steels that have beenmetallically coated, and have undergone a chromate treatment. An organic or organic-silicate 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 coatings may prevent direct resistance welding. The composite 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 chromium, nickel, tin, zinc, copper, or cadmium. Chromium and nickel platings have welding schedules similar to an equivalent gauge of uncoated steel; however, an adjustment in welding current may be required. When welding plated steels, care must be taken to provideadequate ventilation 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 plating in the area of the weld.



4.23 SurfaceConditions. Prior to welding, the workpiece surface should be free of contaminants which may adversely affect weld quality. Zinc-coated steels can oxidize to form zinc oxide, or 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 a 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 aluminum. Care must be exercised during cleaning operations to remove the aluminum oxide layer only and not the aluminum coating. 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



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(8) Phosphate. Phosphate coatings have high electrical resistance and phosphate-coated steels are difficult to weld. A pulsation or upslope of welding current may be required to break through some of the coatings discussed above because of their high electrical resistance.



(3) had-tin alloy (Terne coating).



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Table 8 Electrode Materialsfor Resistance Welding Class



RWMA Designation



Group A-Copper Base Alloys Cadmium copper



Class 1



Zirconium copper



1.16200 1.18200 1.15000



Class 2



Chromium copper Chromium zirconium copper



2.18200 2.18150



Class 3



Beryllium copper (Co)



Beryllium copper (Ni) Beryllium free



3.17500 3.17510 3.18000



Class 4



Beryllium copper



4.17200



Class 5



Aluminum bronze



5.95300



Group B-Refractory Metal or Refractory Metal Composites Class 10



tungstenCopper



(45%Cu/55% W)



10.74450



Class 11



tungstenCopper



(25%Cu/75% W)



11.74400



Class 12



tungstenCopper



(20%CUBO%W)



12.74350



Class 13



Tungsten



13.74300



Class 14



Molybdenum



14.42300



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Group C-Specialty Materials Class 20



20.15760



. 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 introduction of new coatings and expanded use of traditional galvanized 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 to sticking to coated material.



HSLA steels. The following sections are comments and discussions pertaining to these data. Additional comments and discussions applicable to carbon and lowalloy steels as well as other metals are presented separately in 4.7.



4.2.4.1 Electrodes (See Table 8) 4.2.4.1.1 ElectrodeMaterial. Industryuses 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 I , materials are relatively weak electrode materials, but they exhibit the highest conductivity. Theycan conduct the increased currents associated with coated steels and cool the face quicker, which can retard alloying between the coating and the electrode.



4.2.4.1.2 ElectrodeShape. There are several standard and nonstandard electrode shapes available (see Figure 1). Seam weld¡-ng 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 workpiece, is also an acceptable configuration.



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Table 9 Spot Welding Parameters for Galvanized Low-Carbon Stee1117



I Electrode3



Mcta14 Thickness mm (in.)



Face



Diameter mm (in.)



Shapeh



T



Net Electrode Force kN (Ib)



0.51 (0.020) 4.76 (0.187) A, B, E 2.1 1 (470) 2.34 (530) 0.64 (0.025) 4.76 (0.187) A, B, E 2.56 (580) 0.76 (0.030) 6.35 (0.250) A, B, E 0.89 (0.035) 6.35 (0.250) A, B, E, F 2.78 (620) E, F 3.11 (700) A, B, (0.040) 6.35 (0.250) 1.02 1.14 (0.045) 6.35 (0.250) A, B, E, F 3.34 (750) A, B, (0.050) E, F 3.56 (800) 7.94 (0.313) 1.27 A, B, E, F 4.45 (1OOO) (0.055) 7.94 (0.313) 1.40 1.52 (0.060) 7.94 (0.313) A, B, E, F 4.56 (1 030) A, B,(0.070) E, F 5.45 (1230) 7.94 (0.313) 1.78 A, B, E, F 6.12 (1380) (0.080) 7.94 (0.313) 2.03 2.29 (O.Ou0) 9.52 (0.375) A, B, E, F 6.67 (1 500) A, B, E, F 7.67 (1 720) (0.105) 9.52 (0.375) 2.67 3.05 (0.120) 9.52 (0.375) A, B, E, F 9.34 (2100)



T



Weld Weldz Current Time (Approx.: :ycles Amps 10 11



12 13 13 14 16 17 18 22 25



31 35 42



Nugget Diameterss Minimum



Minimum



Minimum



Contact Overlap mm (in.)



Weld Minimum Spacing Satisfactory Setup mm (in.) mm (in.) mm (in.)



Shcar Strength kN (Ib)



11.2 (0.44) 11.9 (0.47) 11.9 (0.47) 13.5 (0.53) 13.5 (0.53) 15.0 (0.59) 15.0 (0.59) 16.0 (0.63) 16.0 (0.63) 16.8 (0.66) 18.3 (0.72) 19.8 (0.78) 21.3 (0.84) 22.4 (0.88)



10900 11500 12300 13500 14 100 14800 15600 16200 17000 18800 19600 20400 22000 24000



9.5 (0.37) 15.9 (0.63) 15.9 (0.63) 19.0 (0.75) 19.0 (0.75) 20.3 (0.94) 20.3 (0.94) 27.0 (1.06) 27.0 (1.06) 30.0 (1.18) 34.9 (1.37) 39.7 (1.56) 42.7 (1.68) 46.0 (1.81)



3.0 (0.12) 3.3 (0.13) 3.6 (0.14) 4.1 (0.16) 4.3 (0.17) 4.8 (0.19) 5.1 (0.20) 5.3 (0.21) 5.6 (0.22) 6.1 (0.24) 6.6 (0.26) 6.9 (0.27) 7.1 (0.28) 7.6 (0.30)



4.6 (0.18) 1.42 (320) 4.6 (0.18) 2.00 (450) 5.1 (0.20) 2.56 (580) 6.4 (0.25) 3.34 (750) 6.4 (0.25) 4.1 1 (920) 6.4 (0.25) 5.12 (1150) 7.9 (0.31) 6.01 (1350) 7.9 (0.31) 7.12 (1600) 7.9 (0.31) 8.23 (1850) 7.9 (0.31) 10.23 (2300) 7.9 (0.31) 12.01 (2700) 9.5 (0.37) 15.35 (3450) 9.5 (0.37) 18.46 (4150) 9.5 (0.37) 22.24 (5000)



General Notes: 1. Welding parameters are applicable to welding two stack joints of one-sided or two-sided galvanized low-carbon steel. 2. Welding parameters are based on single-phase a-c 60 Hz equipment. 3. Welding parameters are applicable when using electrode materials included in R W M A Classes 1,2, and 20. 4. Metal thicknesses represent the actual thicknessof the sheets being welded. In the case of welding two sheets of different thicknesses, use the welding parameters for the thinner sheet. 5. Nugget diameters are listed as: -the minimum diameter that is recommended to be considered a satisfactoryweld. -the initial aimsetup nugget diameter that is recommended in setting up aweld station to produce nuggets that consistently surpess the satisfactory weld nugget diameter for a given number of production welds. 6. Electrode shapes listed include: A-pointed, B-domed, E-truncated, F-radiused. Figure I shows these shapes. 7. These recommendations are based on available weld schedules representing recommendationsfrom resistance welding equipment suppliers andusers. ~



4.2.4.13 Electrode Life. Electrode life can be defined as the number of welds that can be made with a pair of electrodes and maintain weld button diameters above a specified minimum value. Coated steel typically shortens electrode lifemore than uncoated steel. The coating may alloy with the copper electrode and result in electrode sticking and pitting of the electrode face. Coatings that contain zinc, aluminum, tin, or cadmium can alloy easily with the copper electrodes. Different coatings result in different electrode wear characteristics.



Coated HS steels typically require higher forces than coated low-strength, low-carbonsteels (see 4.1.3.2).



4.2.43 Weld Time. Coated steel requires longer weld time than uncoated steel. Weld time may need to be increased as the coating thickness increases. 4.2.4.4 Hold Time. Short hold time may be necessary for coated steels in order to reduce electrode sticking. Coated HS steels may require very low hold time (see 4.1.3.3). 4.2.4.5 Temper Time. Temper time may be incorporated into the welding schedule when welding coated HS steels and medium-carbon steels. These steels may require heat treatment after being welded in order to improve the mechanical properties of the weld. After completing the weld, the welding cycle will go through a quench time (sometimes referred to as the cool time), during which no current flows through the workpiece, and the weld is rapidly cooledby the electrodes. The temper time follows the quench time. Tempering is obtained



4.2.4.2 Net Electrode Force. Coated steels typically require higher electrode forces t h a n uncoated steels. This is especially true for steels with multilayered coatings or primers. Phosphate coatings have very high electrical resistances and may prevent the passageof current at low electrode forces. Steels with thin phosphate coatings can be welded satisfactorily; however, even at higher electrode forces, slight variations i n phosphate coating thickness can result in inconsistent weld quality. 11



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Table 10 Spot Welding Parameters for Galvannealed Low-Carbon Stee1117 Nugget Diameterss



Electrode3 Mcta14



mm (in.)



FdCe



Diameter Thickness mm (in.) Shape6



Weld Net Electrode Weld2 Current



Force kN (Ib)



1.67 (380) 0.51 (0.020) 5.08 (0.200) A, B, E 1.78 (400) A, B, E (0.025) 5.08 (0.200) 0.64 2.00 (450) E A, B, (0.030) 5.08 (0.200) 0.76 0.89 (0.035) 6.35 (0,250) A, B, E, F 2.67 (600) 1.02 (0.040)6.35 (0.250) A, B, E, F 2.89 (650) 1.24 (0.045) 6.35 (0.250) A, B, E,F 3.34 (750) 1.27 (0.050) 7.94 (0.313) A, B, E, F 3.56 (800) 1.40 (0.055) 7.94 (0.313) A, B, E, F 4.00 (900) 1.52 (0.060) 7.94 (0.313) A, B, E, F 4.45 (1 O00) B, E, F 5.34 (1 200) 7.94 (0.313) A, 1.78 (0.070) 2.03 (0.080) 7.94 (0.313) A, B,E, F 5.78 (1 300) A, B, E, F 6.67 (1 500) (0.090) 9.52 (0.375) 2.29 A, B,(0.105) E, F 8.0 1 (1 800) 9.52 (0.375) 2.67 A, B,(0.120) E, F 9.34 (2100) 9.52 (0.375) 3.05



Time (APProx Cycle! Amps



-



6 7 8 9 10



11 12 13 14 16 18 20 23 26



-



Minimum



Minimum



(hltdct Overlap mm (in.)



Weld Minimum Spacing Satisfactor) Setup mm (in.) mm (in.) mm (in.)



8000 1 1.2 (0.44) 9000 11.9 (0.47) 10 500 1 1.9 (0.47) 11 500 13.5 (0.53) 12 500 13.5 (0.53) 13 O00 15.0 (0.59) 14 O00 15.0 (0.59) 14 500 16.0 (0.63) 15 O00 16.0 (0.63) 16 500 16.8 (0.66) 17 500 18.3 (0.72) 19 000 19.8 (0.78) 20 o00 21.3 (0.84) 21 o00 22.4 (0.88)



9.5 (0.37) 15.9 (0.63) 15.9 (0.63) 19.0 (0.75) 19.0 (0.75) 23.9 (0.94) 23.9 (0.94) 27.0 (1.06) 27.0 (1.06) 30.0 (1.18) 34.0 (1.37) 39.7 (1.56) 42.7 (158) 46.0 (131)



2.5 (O. 10) 3.1 (0.12) 3.6 (0.14) 4.1 (0.16) 4.8 (O. 19) 5.1 (0.20) 5.6 (0.22) 6.1 (0.24) 6.6 (0.26) 7.1 (0.28) 7.4 (0.29) 8.1 (0.32) 8.4 (0.33) 8.6 (0.34)



Minimum Shear



Strength kN (Ib)



5.1 (0.20) 1.42 (320)



5.1 (0.20) 2.00 (450) 5.1 (0.20) 2.56 (580) 6.4 (0.25) 3.34 (750) 6.4 (0.25) 4.11 (920) 6.4 (0.25) 5.12 (1150) 7.8 (0.31) 6.01 (1350) 7.8 (0.31) 7.12 (1600) 7.8 (0.31) 8.23 (1850) 7.8 (0.31) 10.23 (2300) 7.8 (0.31) 12.01 (2700) 9.5 (0.37) 15.35 (3450) 9.5 (0.37) 18.46 (4150) 9.5 (0.37) 22.24 (5000)



General Notes: 1. Welding parameters are applicable lo weldingtwo stack joints of one-sided or two-sided galvannealedsheets of low-carbon steel. 2. Welding parameters are based on single-phase a-c 60 Hz equipment. 3. Welding parameters are applicable when using electrode materials included in RWMAClasses 1,2, and 20. 4. Metal thicknesses represent the actual thicknessof the sheetsbeing welded. In the case of welding two sheets of different thicknesses, use the welding parameters for the thinner sheet. 5. Nugget diameters are listed as: “the minimum diameter that is recommended to be considered asalishctory weld. surpass the satisfactory -the initial aimsetup nuggetdiameter that is recommended in setting up a weld station to produce nuggets that consistently weld nugget diameter for a given number of productionwelds. h. Electrode shapes listed include: A-pointed, B-domed, &truncated, F-radiused. Figure 1 shows these shapes. 7. Thcse recornmendations are based on available weld schedules representing recommendations rrom resistance weldingequipment suppliers andusers.



--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



for the weld nugget. For this reason, increased coating weights may require higher welding current or longer weld 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 decreased current density as compared to uncoated steel. 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 thatfor uncoated steel. Zinc- and zinc-alloy coated steels require higher current than uncoated steels. Cadmiumand tin-coated steels require welding schedules similar to zinc-coated steels, but may require lower currents. Aluminum- and aluminum-alloy coated



by applying an additional current, the magnitude of which is a fractional value of the original welding current. The weld should be cooled to a temperature below the critical temperature for martensite formation before application of the tempering current. The tempering current must not remelt the weld nugget, and should not reheat the weldabove 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 presence 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 nuggetin the form of an annular ring. 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



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Table 11 Spot Welding Parameters for GalvanizedHSLA Steel'? Minimum Yield Strengths345,415,480,550, and 620 MPa (50,60,70,80, and 90 ksi)



Metal4 Thickness mm (in.)



-r



Electrode'



Face Diameter mm (in.)



Shape6



Weld Current Amps 480, 550,



Minimum Contact Overlap mm (in.)



345 and and +ILI" Net 115 MPa 620 MPd Electrode Weld2 and (70,80, (50 Time 60 ksi) and 90 ksi) Force Grades kN (Ib) Cycle! Grades



0.51 (0.020) 4.76 (0.187) A, B, E 2.00 (450) 0.64 (0.025) 4.76 (0.187) A, B, E 2.22 (500) A, B, E 6.35 (0.250) 0.76 (0.030) 2.42 (540) A, B, E, F 2.89 (650) 6.35 (0.250) 0.89 (0.035) 1.02 (0.040) 6.35 (0.250) A, B, E, F 3.00 (670) 1.24 (0.045) 6.35 (0.250) A, B, E, F 3.43 (770) A, B,(0.050) E, F 3.67 (830) 7.94 (0.313) 1.27 1.40 (0.055) 7.94 (0.313) A,B,E, F 4.56 (1030) A,B, E, F 5.16 (1160) 7.94 (0.313) 1.52 (0.060) A, B,(0.070) E, F 5.60 (1260) 7.94 (0.313) 1.78 A, B,(0.080) E,F 6.18(1390) 7.94 (0.313) 2.03 A, B,(0.090) E, F 8.01 (180) 9.52 (0.375) 2.29 A, B,(0.105) E, F 8.14 (1830) 9.52 (0.375) 2.67 3.05(0.120) 9.52 (0.375) A, B, E, F 9.70 (2180)



B



*



10 10 11 12 12 13 14 15 17 21 23 29 35 42



8600 7900 1 1.1 (0.44) 9400 8600 1 1.9 (0.47) 9 900 8 800 11 .Y (0.47) 11 200 10 100 13.5 (0.53) 11 500 10 200 13.5 (0.53) 11 200 12300 15.0 (0.59) 12 700 11 300 15.0 (0.59) 13400 14600 16.0 (0.63) 13 700 15 O00 16.0 (0.63) 15200 14200 16.8 (0.66) 14 700 15 18.3 700 (0.72) 15 500 1619.8 500(0.78) 21.4 (0.84) 16800 15800 I 6 700 17 22.4 (0.88) 800



Nugget Diameterss



E



+I Minimum Weld Spacing $to



$



mm (in.)



ICDo



Minimum Satisfactory setup mm (in.) mm (in.)



9.5 (0.37) 3.1 (0.12) 15.9 (0.63) 3.3 (0.1 3) 15.9 (0.63) 3.6 (O. 14) 19.5 (0.75) 4.1(0.16) 19.5 (0.75) 4.3 (0.17) 23.8 (0.94) 4.8 (0.19) 23.8 (0.94) 5.1 (0.20) 26.9 (1.06) 5.3 (0.21) 26.9 (1.M) 5.6 (0.22) 30.0 (1.18) 6.1 (0.24) 34.9 (1.37) 6.6 (0.26) 39.6 (1.56) 6.9 (0.27) 42.7 (1.68) 7.1 (0.26) 46.0 (1.81) 7.6 (0.30)



4.6 (O. 18) 4.6 (0.18) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 7.9 (0.31) 7.9 (0.31) 7.9 (0.31) 7.9 (0.31) 7.9 (0.31) 9.5 (0.37)



General Notes: 1. Welding parameters are applicableto welding twostack jointsof one-sided or two-sided galvanized high-strength low-alloysteels. 2. Welding parameters arebased on single-phase a-c60 Hz equipment. 3. Welding parameters are applicablewhen using electrode materials included in RWMA Classes 1.2, and 20. 4. Metal thicknesses represent the actual thickness of the sheets being welded. I n the caseof welding two sheetsof different thicknesses,use the welding parameters forthe thinner sheet. 5 . Nugget diameters arelisted as: -the minimum diameter that is recommended to be considereda satisfactory weld. consistently surpassthe satisfactory -the initial aim setup nugget diameter that is recommended i n setting up a weld station to produce nuggets that weld nugget diameter for a given number of production welds. 6. Electrode shapes listed include: A-pointed, E-domed, E-truncated, F-radiused. Figure 1 shows these shapes. 7. These recornmendationsare based on available weld schedules representing recommendations from resistance welding equipment suppliers and users.



Table 12 Seam Welding Parameters for Galvanized Low-Carbon Steel' Electrode2 Metal Thickness mm (in.) 0.25 (0.010) 0.53 (0.021) 0.78 (0.031) 1 .O2 (0.040) 1.27 (0.050) 1.57 (0.062) 1.98 (0.078) 2.39 (0.094) 2.77 (0.109) 3.18 (0.125)



Wheel Body Width mm (in.)



Contact4 Face Width mm (in.)



4.76 (0.187) 9.52 (0.375) 4.76 (O. 187) 9.52 (0.375) 12.70 (0.500) 6.35 (0.250) 6.35 (0.250) 12.70 (0.500) 7.94 (0.313) 12.70 (0.500) 7.94 (0.3 13) 12.70 (0.500) 9.52 (0.375) 15.88 (0.625) 15.88 (0.625) 11.11 (0.437) 19.05 (0.750) 12.70 (0.500) 19.05 (0.750) 12.70 (0.500)



Net Electrode Force kN (Ib) 2.2 (500) 2.7 (600) 4.0 (900) 4.9 (1 100) 5.8(130) 6.7 (1500) 7.6 (1700) 8.5 (1 900) 9.3 (2100) 10.2 (2300)



Weld On Time Cycles



Weld Off Time Cycles



2 2 3 3 4 4 6 7 9 11



1 2 2 3 3 4 5 6 6 7



Welding Current Amps



Minimum3 Contact Overlap mm (in.)



10 O00 2.0 (80) 381 (15) 13 O00 1.9 (75) 305 (12) 15 O00 1.8 (71) 254 (10) 17 O00 1.7 (67) 239 (9) 19 O00 1.6 (63) 22Y (8) 21 O00 178 (7) 1.6 (63) 22 500 1.4 (55) 152 (6) 24 O00 140 (5.5) 1.3 (51) 25 O00 1.2 (47) 127 (5) 26 O00 114 (4.5) 1.1 (43)



9.5 (0.37) 11.1 (0.44) 14.2 (0.56) 14.2 (0.56) 14.2 (0.56) 16.0 (0.63) 17.5 (0.69) 19.0 (0.75) 20.6 (0.81) 22.2 (0.88)



Welding Speed m/min (in./min)



Welds per Meter (in.)



General Notes: I . Welding parameters are applicablefor seam welding low-carbon galvanized steels. 2. Welding parameters are applicableusing electrode materials included in RWMA Classes 1. 2, and 20. 3. For large assemblies, the minimum contacting overlap should be increased 30%. 4. The contact face widths in the lable are for flat Pace with bevel sides electrode setups. An alternative is a 75 mm (3 in.) radiused contact face that would be across the entire wheel body width.



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TYPE "A" POINTED



TYPE 'B" DOME



TYPE "C" FLAT



TYPE "D" OFFSET



TYPE "E" TRUNCATED



TYPE "F RADIUS



Figure 1-Standard RWMA Nose or Tip Geometriesof Spot Welding Electrodes



--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



(2) Aluminum has a narrow plastic temperature range. This and its high thermal expansion and contraction may require the use of special weld force application sequences utilizing rapid follow up, along with low inertia equipment for some applications. (3) Aluminumreadily oxidizes on the surface, producing a high and inconsistent resistance. Removal of this oxide requires a chemical or mechanical cleaning process. (4) Aluminum alloys fall into two general classifications, heat treatable and non-heat treatable. The non-heat treatable alloys may be hardened by cold working to some degree. Table13 shows the alloy designationgroups and major alloying elements. An indication is also given



steels may require higher current compared to zinccoated and uncoated steels. Aluminum-zinc-coated steels require currents slightly less than for zinc-coated steels. Spot welding schedules for zinc-based primer and organic compositecoated steels are similar to those for metallic-coated steels, but may require lower welding currents. Series or parallel 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 steels.



4.2.5 Seam Welding. Seam welding coated steel requires 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 cracking in resistance seam welds.



Table 13 Basic Aluminum Alloy Groups Major Designation' Elements Alloying



43. Aluminum Alloys



90.0%Min. Aluminum



43.1 Introduction. The resistance welding of aluminum and aluminum alloys is considerably different from other metals due to the physical and chemical properties described below: (1) Aluminum 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.



Copper



Manganese Silicon Magnesium Magnesium and Silicon Zinc



1xxx 2xxx2 3xxx 4xxx sxxx



hxxx2



7xxx2



General Notes:



,.



Association designations.



2. Heat-treatable



alloys.



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as to whether the alloy designation is considered heat treatable. In general, the high-strength heat treatable alloys (2000, 6000, and 7000 series) have a greater tendency toward weld cracking and porosity than other alloys. ( 5 ) The temper ofan 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 beclosely monitored to control this condition. The weldability of various alloys and tempers in similar 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 cases, 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 weldedas soon as possible after cleaning. The acceptable holding period, or elapsed 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 particular alloy, and other factors. The surface may be cleaned, either chemically or mechanically, as described below: (1) Chemical Cleaning.The chemical solution cleaning process is desirable for large production volumes. Several steps are involved in the cleaning. A non-etching alkaline cleaning solution should be used first to remove heavy oils or grease, followed by a water rinse. Use precaution when handling alkaline (caustic) solutions. They can cause chemicalburns 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 remove 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 maintainedatthe proper strengths to ensure satisfactory surface preparation. The concentration may be determined by titration, and additions of chemicals to the solutions should be made when necessary. The cleaning effectiveness of the



solutions can be adversely affected by contamination. Contaminated solutions should be drained and replaced. The principaladvantages of chemical cleaning are low unit cost, large production capacity, and uniform results. The principal disadvantages are high capital investment, exacting controls, and the cost and difficulty of waste disposal. (2) MechanicalCleaning, The useofmechanical cleaning is generally restricted to small productionquantities or isolated spots on large pieces where it is not necessary or economical to clean the entire piece. Mechanical cleaning is recommended when lap joints are present that canentrap chemical solutions. A precleaner, suchas avapor degreaseror alkaline solution, 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 cloth, or abrasive-impregnated nylon wheel. Wire brush bristles should not exceed 0.13 mm (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 highunit cost, because 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, it is impractical to specify welding parameters for every condition or combination. The parameters presented are for the most commonly welded alloys and thicknesses. Althoughno seam welding data are given, seam welding parameters can be developed. Some of these spot welding data can be usedin developing the seam welding schedules because of the similarity of the two processes. Higher currents are generally needed in seam welding to overcome the effectof current 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 aluminum alloys as well as well as other metals are presented separately in 4.7. 433.1 Electrodes. RWMA Group A, Class 1, copper electrodes are the most commonly used for resistance welding aluminum and its alloys. RWMA Class 1 15 --``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



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Table 16 Spot Welding Parameters for Aluminum Alloys on Standard Single-Phase A-C Type Equipment2 Electrode Diameter and Shape'



Sheet Thickness mm (in.)



D mm (in.)



0.41 (0.016) 0.51 (0.020) 0.64 (0.025) 0.81 (0.032) 1.o2 (0.040) 1.27 (0.050) 1.h0 (0.063) 1.80 (0.071) 2.03 (0.080) 2.29 (0.090) 2.54 (O. 100) 3.18 (0.125)



15.9 (0.63) 15.9 (0.63) 15.9 (0.63) 15.9 (0.63) 15.9 (0.63) 15.9 (0.63) 15.9 (0.63) 15.9 (0.63) 22.2 (0.87) 22.2 (0.87) 22.2 (0.87) 22.2 (0.87)



r



I



Radius mm (in.)



Top Electrode



3ottom Electrode



1



Flat



1 2 2



Flat



3



Flat Flat Flat Flat



3



Flat



4 4 6 6 6



4 4 6 6 6



3



Net Electrode



Force (Weld) kN (Ib)



1.42 (320) 1.51 (340) 1.73 (390) 2.22 (500) 2.67 (600) 2.96 (660) 3.34 (750) 3.56 (800) 3.83 (860) 4.23 (950) 4.67 (1050) 5.78 (1300)



Welding Current Approx. Amps



Welding? Time Approx. (Cycles)



15 O00 18 O00 21 800 26 o00 30 700 33 o00 35 800 35 o00 41 800 46 o00 56 o00 76 o00



4 5



6 7 8 8



10 10 10 12 15 15



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 critical. If applied too late, the weld will have already solidified, 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 weldto develop. The actual timing of the forging force may be determined by measuring the weld force and current as a function of time.



copper has high electrical and thermal conductivities but is not heat treatable. I f higher strength electrodes are needed, RWMA Group A, Class 2, copper electrodes may be used. The lower electrical and thermal conductivities of the Class 2 copper alloy makes it less suitable for welding aluminum except in those cases requiring higher electrode strength or in combination with Class 1 electrodes 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 uponsolidification than steel. Use of a low-inertia, low-friction welding head assures rapid follow-up to reduce weld defects. In seam welding, higher quality welds are produced with indexing electrode wheels rather than with wheels turning during welding. The variable force cycle, in which the weld is made at a low force, followed by application of a carefully timed



4 3 3 3 Weld Time. Short weld times are desirable when welding aluminum becauseof its high thermal conductivity. 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 resultin porous, cracked welds, or weld expulsion. 43.3.4 Weld Current. Higher currents are generally required for welding aluminum than steel and some



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General Notes: 1. Electrode material: R W M A Class 1. 2. 'Qpesof aluminum alloy: 1 IO&H12-H18,300)3-H12H-H18,3OM-H32-H3X,5052-H32-H38,50150-H32-H3X,5356-H32-H38, 606l-T4-T6,6063-T5-T6. 3. A-C 60 Hz equipment.



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Table 18 Spot Welding Parameters for Aluminum Alloys on Three-phase RectifierType Equipment Electrode Diameter and Shape'.2 RADIUS



-i Sheet Thickness mm (in.)



5 I-D



D



mm (in.)



Radius mm (in.)



15.9 (0.63) 76 (3.0)



1.27 (0.050) 1 . 6 0 (0.063) 1.80 (0.071) 2.03 (0.080) 2.29 (0.090) 2.54 (0.100) 3.18 (0.125)



15.9 (0.63)



15.9 (0.63) 15.9 (0.63) 22.2 (0.87) 22.2 (0.87) 22.2 (0.87) 22.2 (0.87)



Post Weld



Forge



Weld



19.0 2.0 (450) 4.4 (980) 5.115.9 (1 150) 2.3 (520) 76 (3.0) (0.63) 22.0 28.0 6.9 (1550) 3.0 (670) 76 (3.0) 15.9 (0.63) 8.0 (1800) 3.2 (730) 76 (3.0) 15.9 (0.63) 1.02 (0.040) (900) 10.0 (2250) 4.0 203 (8.0) 12.9 (2900) 4.9 (1 100) 203 (8.0) 5.3 (1 190) 2031.44 (3240) (8.0) 203 (8.0) 16.9 (3800) 6.5 (1460) 19.1 (4270) 7.6 (1710) 203 (8.0) 61.0 22.2 (4990) 8.5 (1910) 203 (8.0) (8.0) 1 1 . 1 (2500) 203 28.9 (6500)



0.41 (0.016) 0.51 (0.020) 0.81 (0.032)



Welding Time4 (Approx.) (Approx.) Cycles2 Amps



Welding Current3 Net Electrode Force kN (Ib)' Heat



Weld 1



None None None 30.0 36.0 38.0 42.0 45.0 49.0 54.0



1



32.0 37.0 43.0 48.0 52.0 56.0



3



5



7 8 9



69.0 10



Post Heat None None None 2 None None 4 4 5 6 6 7 8 9 10



General Notes: 1. Electrode material: RWMA Class 1. 2. The top and bottom electrodes should have the same tip radius, or one has a radius tip and the other a flat tip. 3. The force and current values for alloys are 2014-T3, T4, Th, 2024-T3, T4,and 7075-Th. Somewhat lower values may be used for alloys such as 5052 and 6061. 4. A-C h0 Hz equipment.



Many of the alloys discussed in this section are precipitation-hardenable. For these alloys, a postweld heat treatment is usually needed to producea hardness in the weld region similar to that of the alloy in the fully heat-treated condition.



other metals because of its higher electrical and thermal conductivities and low surface electrical resistance after cleaning. Current sloping is frequently used on aluminum to control the cooling rate to reduce welddefects. --``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



4.4 Stainless Steels, Nickel, Nickel-Base Alloys, and Cobalt-Base Alloys 4.4.1 Introduction. Mostof these metalscanbe readily resistance welded.The cast precipitation-hardenable nickel-base alloys with low ductility are among those that are normally difficult to resistance weld without 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 magnification. However, when it is properly etched and at enough magnification, the area can beseen completely filled with dendritic material as shown in Figure 2. Based on its dendritic structure, the area appears caused by either incipient 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.



Figure 2"Coring in Nickel Alloy 718 (UNS N07718) Resistance Seam Weld, 200X 21



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Table 19 Spot Welding Parameters for Aluminum Alloys on Three-phase Frequency Converter Type Equipment (Single Impulse Welds) Electrode Diametcr and Shape



Net Electrode Force kN (Ib)



Weld Current (APProx-) Amps x loo0



D



Radius



mm (in.)



mm (in.)



Weld



Forge



Weld



Post Heat



15.9 (0.63) 7.9 (0.31)



76 (3.0) 254 (10.0)



2.2 (500) 2.7 (600)



2.2 (500) 5.3 (1 200)



26



None



19



4.0



MIL^



15.9 (0.63) 7.9 (0.31)



76 (3.0) 254 (10.0)



2.2 (500) 2.7 (600)



5.3 (1 200) 7.1(1 600)



34 25



0.81 (0.032)



CO"' MILz



15.9 (0.63) 9.5 (0.37)



102 (4.0) 254 (10.0)



2.7 (600) 3.1 (700)



5.8 (1 300) 8.0 (1 800)



1.02 (0.040)



CO"' MILZ



15.9 (0.63) 9.5 (0.37)



102 (4.0) 254 (1 0.0)



3.1 (700) 3.6 (800)



1.27 (0.050)



COM"



15.9 (0.63) 11.1 (0.44)



102 (4.0) 254 (10.0)



15.9 (0.63) 12.7 (0.50)



MIL^



Sheet Thickness mm (in.) 0.51 (0.020)



COMML



8.5 6.3



1 1



3 2



36 30



9.0 7.5



1 1



4 2



6.7 (1 500) 8.9 (2 OOO)



42 40



12.6 12.0



1 2



4 4



3.6 (800) 4.0 (900)



8.0 (I 800) 10.2 (2 290)



46 43



13.8 12.9



1 2



5 4



152 (6.0) 254 (10.0)



4.4 (1 000) 5.8 (1300)



8.9 (2 000) 13.3 (2 990)



54 51



18.9



2 3



5 6



15.9 (0.63) 15.9 (0.63)



152 (6.0) 254 (10.0)



5.3 (1200) 7.1 (1600)



11.1 (2500) 16.0 (3 600)



61 57



20.0



2 3



6 6



CO"' MILZ



22.2 (0.87) 15.9 (0.63)



152 (6.0) 254 (1 0.0)



6.2 (1400) 8.0 (1800)



12.5 (2 810) 18.2 (4 OW)



65 63



22.8 22.1



3 4



8



COMM~



22.2 (0.87) 15.9 (0.63)



152 (6.0) 254 (1 0.0)



7.1 (1600) .0.7 (2400)



14.2 (3 1W) 23.6 (5 310)



75 73



30.0 29.2



3 4



8 8



MIL^



22.2 (0.87) 22.2 (0.87)



203 (8.0) 254 (10.0)



8.9 (2000) 2.5 (2810)



17.8 (4 OOO) 30.2 (6 790)



85 81



34.0 32.4



3 5



8 10



COM" MIL*



22.2 (0.87) 22.2 (0.87)



203 (8.0) 254 (10.0)



!O.O (4500)



22.2 (4 990) 44.5 (10 OOO)



100 100



45 .O 45 .O



4 5



10 10



COM"



COM"



MIL^ 1.80 (0.071) 2.03 (0.080) 2.29 (0.090)



COM"



MIL^ 2.54 (0.100)



3.18 (0,125)



Post Heat None



MIL^ 1.60 (0.063)



Weld 1i 2 1



MIL^ 0.64 (0.025)



Welding Time Cycles (60per sec.)



CO"'



7.8 (4000)



17.9 21.4



2



6



General Notes: --``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



1 . COMM = commercial requirements. 2. M I L = military requirements. 3. Electrode material: RWMA Class 1.



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(1) Plate the faying surfaces with a higher electrical resistance metal (e.g., tin or nickel), to compensate for the low electrical resistance of the base metal. This technique can greatly improve the resistance weldability of copper. However, since the plating will alter the chemical composition of the weld, itsacceptability should be evaluated based on the service requirements of the welded joint. (2) Use electrodes faced with a refractory metal like tungsten or molybdenum (e.g., RWMA Group B, Classes 13 and 14), to reduce alloying and sticking of the electrodes to the workpiece. (3) Use a short weld time to minimize metal expulsion and sticking of the electrode to the 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 maintainpressure on the joint to prevent metalexpulsion.



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 can cause dizziness. Other solvents are flammable and require good ventilation; therefore, proper precautions should be taken. 4.43 Weld Parameters. The data shown in Tables 20 through 37 are offered as a guide to develop welding schedules for stainless steels, nickel, nickel-base and cobaltbase alloys. The following sections are comments and discussions pertaining to these tables. Additional comments and discussions applicable to the above metals are presented separately in 4.7. 4.43.1 Electrodes. Most of these metalsretain their high strength at elevated temperatures. Therefore, electrodes 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 higher strength than RWMA Group A, Class 1, which are not heat treatable.



4.6 Titanium and Titanium Alloys.Titanium and its alloys 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 interstitial elements as hydrogen, carbon and oxygen. Increases in the concentration of these elements can significantly decrease the weld ductility and toughness. Scale-free surfaces may be welded after degreasing or after degreasing plus pickling. Pickling may be carried out in a water solution containing 2 to 5 percent hydrofluoric acid and 30 to 40 percent nitric acid by volume. Pickling acid, hydrofluoric acid and nitric acid are hazardous to the skin and eyes. Hazardous fumes can be produced by these acids and violent chemical reactions can result when acids are mixed with other chemicals, especially those with basic pHs. Acids can also eat through some clothing. Use precautions when working near or with acids. Strict precautions are necessary in their use and disposal. Acids should be added to water, not water into acid. Pickling, hydrofluoric and nitric acids cause chemical burn to the skin. Mix and use pickling acid in a properly vented area. Before use, read and understand the manufacturer’s instructions, Material Safety Data Sheets (MSDSs), and your employer’s safety practices. Rinse the surfaces in clean water and dry them after pickling. The data shown in Table 39 may be used as a guide to develop spot welding schedules for titanium alloy



4.43.2 Net Electrode Force. A higher electrode force is needed for most of these metals as compared with carbon steels. 4.433 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 either a lower thermal conductivity or smaller face area, or both, on the stainless steel side. The lower thermal conductivity or smaller face decreases the heat conducted away from the stainless steel by the electrode. A smaller face area will also concentrate the weld current or heat into a smaller area. 4.5 Copper and CopperAlloys. Copper and copper alloys can be resistance spot welded although copper and some of the copper alloys have very high electrical and thermal conductivities. Electrical and thermal conductivities are among the properties of a metal that can significantly 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 techniques may be used to facilitate resistance spot welding of these metals:



--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



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m



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Table 22 Seam Welding Parameters for Stainless Steels’ Electrode Width and Shape*



Off Time



@”(3 in.)mm 76



Sheet Thickness mm (in.) 0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.012) 0.36 (0.014) 0.41 (0.016) 0.46 (0.018) 0.53 (0.021) 0.64 (0.025) 0.78 (0.031) 1.O2 (0.040) 1.27 (0.050) 1.57 (0.062) 1.78 (0.070) 1.98 (0.078) 2.39 (0.094) 2.77 (0.109) 3.18 (0.125)



4-4



RADIUS



Minimum Contacting Overlap5 mm (in.)



Net Electrode



W mm (in.)



Force kN (Ib)



4.8 (0.19) 4.8 (0.19) 4.8 (0.19) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 9.5 (0.37) 9.5 (0.37) 9.5 (0.37) 12.7 (0.50) 12.7 (0.50) 15.9 (0.63) 15.9 (0.63) 15.9 (0.63) 19.0 (0.75) 19.0 (0.75)



1.33 (300) 1.56 (350) 1.78 (400) 2.00 (450) 2.22 (500) 2.67 (600) 2.89 (650) 3.1 1 (700) 3.78 (850) 4.45 (1000) 5.78 (1 300) 7.12(1600) 8.23 (1 850)



9.56 (2150) 10.23 (2300) 1 1.34(2550) 26.47 (5950) 14.68 (3300)



On Time Cycles4 2 2 3 3 3 3 3 3 3 3 3 4 4 4



for Maximum Maximum Speed Weld (PrcssureSpeed Tight) m/min Cycles4 (in./min) 1



1



2 2 2 2 2 2 3 3 4 4 5 5 6 6 7 6



4 5



5 6



1.5 (60) 1.7 (67) 1.1 (45) 1.2 (48) 1.3 (51) 1.3 (51) 1.4 (55) 1.4 (55) 1.3 (51) 1.3 (51) 1.2 (47) 1.1 (45) 1.o (40) 1.1 (45) 1.o (40) 0.9 (35) 1.o (40)



1.o (40)



Welds Per Meter



(in.) 510 (20) 460 (18)



410 (16) 380 (1 5) 360 (14) 360 (14) 330 (1 3) 330 (13) 300 (12) 300 (12) 280 (11) 250 (10) 250 (10) 230 (9) 230 (9 230 (9) 200 (8)



200 (8)



Welding Current (APPrOx.) Amps 4000 4600 5000 5600



6 200 6 700



7 300 7900 9 200 10 600 13 000 14 200 15 100 15 900



16 500 16 600 16 800 17 000



B



+ILI+



&i9



6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 7.9 (0.31) 7.9 (0.31) 7.9 (0.31) 7.9 (0.31) 9.5 (0.37) 11.1 (0.44) 11.1(0.44) 12.7 (0.50) 15.9 (0.63) 15.9 (0.63) 17.5 (0.69) 17.5 (0.69) 19.0 (0.75) 20.6 (0.81) 22.2 (0.87)



General Notes: 1 . Types of steel-301,302,303,304,308, 309,310,316,317,321,347, and 349. 2. Electrode material: RWMA Class 3. 3. For large assemblies, minimum contacting overlap indicated should be increased30 percent. 4. A-C 60 Hz equipment.



4.7 Welding Data Comments and Discussions Applicable to Various Metals. The following comments and discussions are applicable to the spot and seam welding data for all of the following: (1) Uncoated carbon and HS steels (2) Coated carbon and HS steels (3) Aluminum alloys (4) Stainless steels, nickel, nickel-base alloys, and cobaltbase 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



--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



Copyright American Welding Society Provided by IHS under license with AWS



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 diameters other than those presented in the tables may be used. However, the welding schedule must be adjusted accordingly (see Figure 1 and Table 40). Care should be exercised to preventexcessive increase or decrease in the face diameter during electrode dressing. 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). Electrode wheels are used in seam welding. Therefore, electrode face width, rather than electrode face diameter, is specified in seam welding. 26 Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004 11:34:02 MDT Questions or comments about this message: please call the Document Policy Group at 303-397-2295.



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Table 23 Spot Welding Parametersfor Annealed Nickel-Copper Alloy3on Single-phase Equipment Electrode Diameter and Shape'*2 Minimum :ontacting Overlap mm (in.)



Sheet Thicknesses mm (in.)



--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



0.13 (0.005) to: 0.13 (0.005) 0.25 (0.010) 0.38 (0.015) 0.53 (0.021)



d mm (in.) Max.



D mm (in.) Min.



4.0 (0.16) 4.0 (0.16) 4.0 (0.16) 4.0 (0.16) 4.0 (O. 16) 4.0 (0.16) 4.0 (0.16) 6.4 (0.25) 7.9(0.031) (0.31) 4.0 (0.16) 0.78 1.60 (0.063) ' 4.0 (O. 16) 16.0 (0.63) 2.36 (0.093) 4.0 (0.16) 16.0 (0.63) 4.0 (O. 16) 16.0 (0.63) 3.18 (0.125) 0.25 (0.010) to: 0.25 (0.010) 4.0 (O. 16) 4.0 (0.16) 4.0 (O. 16) 4.0 (0.16) 0.38 (0.015) 4.0 (0.16) 4.0 (0.16) 0.53 (0.021) 0.78 (0.031) 4.0 (O. 16) 4.0 (0.16) 4.0 (O. 1 6) 7.9 (0.31) 1.60 (0.063) 2.36 (0.093) 4.0 (O. 16) 16.0 (0.63) 3.18 (0.125) 4.0 (O. 1 6) 16.0 (0.63) 0.38 (0.015) to: 4.8 (0.19) 0.38 (0.0 15) 4.8 (0.19) 0.53 (0.021) 4.8 (0.1 9) 4.8 (O. 19) 4.8 (0.19) 4.8 (0.19) 0.78 (0.031) 1.60 (0.063) 4.8 (O. 19) 16.0 (0.63) 2.36 (0.093) 4.8 (0.19) 16.0 (0.63) 3.18 (0.125) 4.8 (O. 19) 16.0 (0.63) 0.53 (0.021) to: 0.53 (0.021) 4.8 (0.19) 4.8 (0.19) 0.78 (0.031) 4.8 (O. 19) 4.8 (0.19) 4.8 (0.19: 1.60 (0.063) 4.8 (0.19) 4.8 (O. 1 9) 16.0 (0.63; 2.36 (0.093) 4.8 (0.19) 16.0 (0.63; 3.18(0.125) 0.78 (0.031) to: 0.78 (0.031) 4.8 (O. 19) 4.8 (0.19; 1 .60 (0.063) 4.8 (0.19) 6.4 (0.25: 4.8 (0.19) 16.0 (0.63: 2.36 (0.093) 3.18 (0.125) 4.8 (O. 1Y) 16.0 (0.63: 1.60 (0.063) to: 7.9 (0.31: 1.h0 (0.063) 7.9 (0.31) 2.36 (0.093) 7.9 (0.31) 16.0 (0.63: 3.18 (0.125) 7.9 (0.31) 16.0 (0.63: 2.36 (0.093) to 9.5 (0.37: 2.36 (0.093) 9.5 (0.37) 9.5 (0.37: 3.18 (0.125) 9.5 (0.37) 3.18 (0.125) to 3.18 (0.125) 12.7 (0.50) 12.7 (0.50



Net Electrode Force kN (Ib)



Weld Time Cycles



Welding Current ,Approx.)



Amps



*I L I" Minimum Weld Spacing



&9



Qto



Q



mm (in.)



Nugget Diameter mm (in.) I+Do



Minimum Shear Strength kN (Ib)



."J CI



5000 6 100 7000 7 200 7400 8000 8600 8 700



6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)



6.4 (0.25) 6.4 (0.25) 4.8 (0.1 9) 7.9 (0.31) 7.9 (0.31) 1 1.1 (0.44) 12.7 (0.50) 12.7 (0.50)



2.5 (0.10) 2.5 (0.10) 2.5 (0.10) 2.8 (0.1 1) 2.8 (0.1 1) 2.8 (0.1 1) 2.8 (0.11) 2.8 (0.1 1)



0.24 (55) 0.27 (60) 0.33 (75) 0.38 (85) 0.42 (95) 0.40 (W) 0.40 (W) 0.42 (95)



4 4 4 4



7 200 8 600 8 200 8 800 9 200 9 900 9 Y00



6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 7.9 (0.31) 6.4 (0.25) 7.9 (0.31) 7.9 (0.31) 6.4 (0.25) 7.9 (0.31) 6.4 (0.25) 6.4 (0.25) 12.7 (0.50) 6.4 (0.25) 12.7 (0.50)



3.0 (O. 12) 3.0 (0.12) 3.3 (0.13) 3.3 (0.13) 3.3 (0.13) 3.6 (0.14) 3.6 (0.14)



0.64 (140) 0.69 (155) 0.76 (170) 0.85 (190) 0.85 (1 90) 0.93 (210) 0.98 (220)



1.33 (300) 1.33 (300) 1.45 (330) 1.45 (330) 1.45 (330: 1.45 (330:



2 6 6 6 8 8



8 600 8 200 Y 300 9 400 9 500 9 500



7.9 (0.31) 6.4 (0.25) 6.4 (0.25) 9.5 (0.37) 6.4 (0.25) 9.5 (0.37) 6.4 (0.25) 11.1 (0.44) 6.4 (0.25) 12.7 (0.50) 6.4 (0.25) 12.7 (0.50)



3.3 (0.13) 3.3 (O. 13) 3.3 (O. 13) 3.6 (O. 14) 3.6 (0.1% 3.6 (0.14:



1.11 (250) 1.31 (290) 1.33 (300) 1.56 (350) 1.60 (360) 1.62 (364)



1.33 (300: 1.45 (330: 1.45 (330: 1.45 (330: 1.45 (330:



12 12 12 12 12



6 200 6 800 7 200 7 700 8 200



7.9 (0.31) 7.9 (0.31) 7.9 (0.31) 9.5 (0.37) 9.5 (0.37)



11.1 (0.44) 11.1 (0.44) 12.7 (0.50) 14.3 (0.56) 14.3 (0.56)



3.3 (0.13: 3.3 (0.13: 3.6 (0.14: 3.6 (0.14 3.6 (0.14



2.00 (450) 2.05 (460) 2.22 (500) 2.36 (530) 2.45 (550)



3.1 1 (700: 3.34 (750' 3.45 (780 3.45 (780



12 12 12 12



10 500 11 200 11 400 1 I 800



9.5 (0.37) 12.7 (0.50) 12.7 (0.50) 12.7 (0.50)



16.0 (0.63) 17.5 (0.69) 19.0 (0.75) 19.0 (0.75)



4.3 (0.17 4.6 (0.18 4.8 (0.19 4.8 (0.19



3.76 (845) 4.05 (910) 4.60 (1034) 4.78 (1075)



2.01 (27M 12.0 1 (27M 12.01 (27M



12 12 12



15 300 15 900 16 200



16.0 (0.63) 28.6 (1.13) 16.0 (0.63: 30.2 (1.19) 16.0 (0.63: 31.8 (1.25:



7.9 (0.3 1 7.9 (0.31 8.1 (0.32



9.16 (2060) 9.70 (2180) 10.50 (2360)



12.28 (276( 12.28 (276(



20 20



22 600 25 O00



19.0 (0.75: 31.8 (1.25; 19.0 (0.75: 31.8 (1.251



9.4 (0.37 9.7 (0.38



17.26 (3880) 19.53 (4390)



!2.24 (500(



30



30 000



22.2 (0.87:



41.3 (1.63:



11.9 (0.47



26.02 (5850)



0.98 (220) 0.98 (220) 0.98 (220) 0.98 (220) 1.11 (250) 1.11 (250) 1.11(250) 1.11 (250)



2



1-20(270) 1.25 (280) 1.25 (280) 1.33 (300) 1.33 (300) 1.45 (330) 1.45 (330)



2 2



2 2 3 4 4 4 4



3



General Notes: 1. Electrode shape may be flat rather than domed, in which case the shear strengths and nugget diameters will be higher and larger than shown in the lable. 2. Electrode material: R W M A Class 1 or Class 2. 3. Nominal chemical composition of nickel-copper alloy (UNS N04400), wt.-%: 66.0 Ni, 31.5 Cu, 1.35 Fe, 0.90 Mn, 0.15 Si, 0.12 C, 0.005 S .



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~~



S T D = A W S C L * L M / C L = L - E N G L 2000 œ 07842b505L3b83



825



œ



AWSCl.lM/C1.1:2000



h



-3.d EE



E



--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



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STDmAWS C l = l M / C l - l - E N G L 2000 D 078112b5 O 5 l 3 b A 4 7 b l D AWS Cl .1M/C1.1:2000



Table 25 Seam Welding Parameters for Annealed Nickel-Copper Alloy’ on Single-phase Equipment Electrode Wheel Width and Shape2



Off Time



Net Sheet Thickness mm (in.) 0.25 (0.010) 0.38 (0.015) 0.53 (0.021) 0.64 (0.025) 0.79 (0.031) 1.57 (0.063)



(Pressure Tight) Cycles



Radius



mm (in.)



3



76 (3.0)



152 152 152 152 152



(6.0) (6.0) (6.0) (6.0) (6.0)



Minimum Contacting Overlap mm (in.)



13.3 (300) 22.2 (500) 2.67 (600) 3.11 (700) 11.1 (2500)



Welding Current (Approx.) Amps



3 6



5 300 7 600 8 700



12 12 12



Y 500 10 O00 19 O00



-I



L



r-



n u



& J



J& ,,



6.4 (0.25) 6.4 (0.25) 7.9 (0.31) 7.9 (0.31) 9.5 (0.37) 16.0 (0.63)



General Notes: 1. Nominal chemical composition of nickel-copper alloy (UNS N04400), wt.-%: 66.0 Ni, 31.5 Cu, 1.35 Fe, 0.90 Mn, 0.15 Si, 0.12 C, 0.(H)5S. 2. Electrode material: RWMA Class 2 (Preferred) or Class 1.



4.73 ElectrodeFaceShape. The electrode face shape influences the weld size, shape and surface indentation. To maintain consistent weld quality, the electrodes may require 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 unequalthicknesses, it is often desirable to use a combination of electrode 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, will produce lower weld penetration in the sheet contacting it. Standard RWMA nose or tip geometries of spot welding electrodes are shown in Figure 1. --``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



(95°F). For adequate cooling, a maximum electrode face thickness (nose thickness) of 13 m m (0.50 in.) with a properly positioned coolant inlet tube is recommended. The coolant inlet tubeshould be cut on an angle at the tip and inserted tocontact the bottomof the water holein the electrode to ensure maximum cooling of the face. If the coolant inlet tube is not properly placed, steam or turbulence may develop within theelectrode tip, reducing heat dissipation. The reduced cooling of the electrode will decrease the electrode life. External water cooling may be used in combination with internal water cooling to provide more effective cooling of the spot welding electrodes. In seam or roll-spot welding, thewheel electrode should be cooled with an external water stream directed at the weld area, cooling both the electrode and workpiece, where practical.



4.7.5 Net Electrode Force. Correct weld forces, for a given combination of current level and weld time, are required to produce welds of optimum nugget size and penetration without expulsion, porosity, cracking, or excessive indentation. Excessively low forces do not provide current uniformity and molten metal containment, and may result in expulsion at the joint or electrode-toworkpiece interface. Excessively high forces produce



4.7.4 Electrode Cooling.Spot and projection welding electrodes should be internally water cooled to prevent overheating which results in electrode sticking and decreased electrode life. Internal coolant flow rate requirements may vary from 1.9 to 5.7 Umin (0.5 to 1.5 gal/min) per electrode, depending on the type of welding system. Water coolant temperature should be less t h a n 35°C 29 Copyright American Welding Society Provided by IHS under license with AWS



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n



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Table 27 Spot Welding Parameters for Annealed Nickel-Chromium Alloy 6003 on SinglePhase Equipment ~



Electrode Diameter and S h a ~ e ' . ~ . ~ Ainimum bntacting Overlap mm (in.)



RADIUS



Sheet Thicknesses mm (in.) 0.13 (0.005) to: O. 13 (0.005) 0.25 (0.010) 0.38 (0.015) 0.53 (0.021) 0.79 (0.031) 1.6 (0.063) 2.4 (0.093) 3.2 (0.125) 0.25 (0.010) to 0.25 (0.010) 0.38 (0.015) 0.53 (0.021) 0.79 (0.031) 1.6 (0.063) 2.4 (0.093) 3.2 (0.125) 0.38 (0.015) to 0.38 (0.0 15) 0.53 (0.021) 0.79 (0.031) 1.6 (0.063) 2.4 (0.093) 3.2 (0.125) 0.53 (0.021) to 0.53 (0.021: 0.79 (0.031: 1.6 (0.063: 2.4 (0.093: 3.2 (0.125; 0.79 (0.031) tc 0.79 (0.031' 1.6(0.063: 2.4 (0.093: 3.2 (0.125: 1.6(0.063) tc 1.h (0.063, 2.4 (0.093' 3.2 (0.125 2.4(0.093) tc 2.4 (0.093 3.2 (0.125 3.2(0.125) tc 3.2 (0.125



&



7000 5 300 5 500 4 800 5 400 5 600 5 800 5600



6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)



4 4 6 6 6 6 6



7900 5 500 5 loo 5600 5 500 5 800 4 600



1 .h0 (360) 1.60 (360) I .78 (400) 1.78 (400) 1.78 (400) 1.78 (400)



6 6 8 8 10 12



1.34 (300) 1.56 (350) 1.78 (400) 2.22 (500) 2.45 (550) 3.11 (700) 3.11 (700) 3.11 (700) 3.34 (750)



Net Electrode Force



-CI



CI ¡+Da



6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 7.9 (0.31) 7.9 (0.31) 9.5 (0.37) 9.5 (0.37) 9.5 (0.37)



2.8 (0.11) 3.0 (O. 12) 3.0 (0.12) 3.3 (0.13) 3.3 (O. 13) 3.8 (0.15) 4.1 (0.16) 3.8 (O. 15)



0.3 (700) 0.44 (100) 0.47 (106) 0.49 (110) 0.53 (120) 0.60 (130) 0.65 (150) 0.60 ( 130)



6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)



6.4 (0.25) 6.4 (0.25) 7.1 (0.28) 7.1 (0.28) 7.9 (0.31: 9.5 (0.37) 9.5 (0.37:



3.0 (O. 12) 3.3 (O. 13) 3.3 (O. 13) 3.3 (0.13) 3.6 (0.14) 3.8 (O. 15) 3.6 (0.14)



0.78 (175) 0.96 (220) 0.96 (220) 1.29 (290) 1.40 (315) 1.56 (350) 1.65 (370)



7 600 8 400 4 600 4 700 4 700 4 600



6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25) 6.4 (0.25)



6.4 (0.25: 6.4 (0.25: 7.1 (0.28: 7.9 (0.3 1: 8.7 (0.34' 9.5 (0.37:



3.0 (0.12) 3.0 (0.12) 3.3 (O. 13) 3.3 (0.13) 4.1(0.16) 4.1 (O. 16)



1.31 (294) 1.29 (2%) 1.65 (370) 1.96 (440) 2.38 (535) 2.49 (560)



12 12 12 12 12



4000 4 100 5 300 5900 6 300



7.9 (0.31) 7.9 (0.31) 7.9 (0.31) 7.9 (0.31) 7.9 (0.31)



11.1 (0.44 11.1 (0.44 11.9 (0.47 12.7 (0.50 12.7 (0.50



3.0 (0.12) 3.0 (0.12) 3.0 (0.12) 3.8 (O. 15) 3.8 (0.15)



2.42 (544) 2.38 (535) 2.58 (580) 2.98 (670) 3.07 (690)



12 12 12 12



6 700 7 100 8 300 8 900



9.5 (0.37) 9.5 (0.37: 9.5 (0.37: 9.5 (0.37:



14.3 (0.56 16.0 (0.63 17.5 (0.69 19.0 (0.75



4.6 (0.18) 4.6 (0.18) 5.1 (0.20) 5.1 (0.20)



4.09 (Y20) 4.29 (964) 5.74 (1 290) 5.38 (1210)



D mm (in.) Min.



4.0 (O. 16) 4.0 (O. 16) 4.0 (O. 16) 4.0 (O. 16) 4.0 (0.16) 4.0 (O. 16) 4.0 (O. 16) 4.0 (O. 16)



4.0 (O. 1 6) 4.8 (O. 19) 4.8 (0.19) 4.8 (0.19) 4.8 (0.19) 16.0 (0.63) 16.0 (0.63) 16.0 (0.63)



1.34 (300) 1.34 (300) 1.34 (300) 1.34 (300) 1.45 (326) 1.45 (326) 1.45 (326) 1.45 (326)



2 4 4 6 6 6 6 6



4.0 (O. 16) 4.8 (0.19) 4.0 (O. 16) 4.8 (0.19) 4.0 (O. 16) 4.8 (0.19) 4.0 (O. 16) 4.8 (O. 19) 4.0 (0.16) 4.8 (0.19) 4.0 (0.16) 16.0 (0.63) 4.0 (0.16) 16.0 (0.63)



1.42 (320) 1.42 (320) 1.42 (320) 1.56 (350) 1.78 (400) 1.78 (400) 1.78 (400)



kN (Ib)



4.8 (0.lY) 4.8 (O. 19) 4.8 (O. I Y) 7.9 (0.31) 16.0 (0.63) 16.0 (0.63)



4.8 (O. 19: 4.0 (O. 16) 4.8 (O. 1 9) 4.8 (0.1 Y' 4.8 (O. 19 4.8 (O. 191 4.8 (O. 1!I 16.0 (0.631 4.8 (O. 19: 16.0 (0.63)



c'



Nugget Diameter mm (in.)



Minimum Shear Strength kN (Ib)



Neid rime :ycles



d mm (in.) Max.



4.8 (O. 1 Y] 4.8 (0.19; 4.8 (0. 19; 4.8 (O. 19: 4.8 (0.19; 4.8 (0.19;



r-



Winimum Weld Spacing (€to.(€ mm (tn.)



*I L



Welding Current Approx.)



-



Amps



4.8 (0.19 4.8 (O. 19 4.8 (O. 19 4.8 (0.19



4.8 (0.19) 7.9 (0.3 1 9.5 (0.37; 16.0 (0.63)



4.8 (O. I Y 7.9 (0.31 14.3 (0.56



9.21 (2070 7.9 (0.3 1 16.0 (0.63: 10.90 (2450 16.0 (0.63: 1 1.57 (2600



12 16 20



12 o00 12 000 12 o00



16.0 (0.63; 28.6 (1.13 16.0 (0.63: 30.2 (1.19 16.0 (0.63: 31.8 (1.25



7.9 (0.3 1) 7.9 (0.31) 8.1 (0.32)



12.41 (2790) 12.23 (2750) 15.21 (3420)



9.5 (0.37 11.1 (0.44



9.5 (0.37 17.21 (3870 11.1 (0.44: 22.69 (5 1O0



20 30



19 o00 20 O 0 0



19.0 (0.75: 30.2 (1.19 19.0 (0.75: 31.8 (1.25



9.4 (0.37) 10.2 (0.401



19.57 (4400) 20.91 (4700)



11.1 (0.44



11.1 (0.44 23.44 (5270



30



20 100



22.2 (0.87



:



33.3 (1.31



1 1.1(0.44: 28.47 (6400)



General Notes: 1. Electrode shape may be flat rather than domedin which ca..e the shear strengths and nugget diameterswill be higher and larger than shownin the table. 2. Electrode material: R W M A Class 2, Class 3. or Class 4. 3. Nominal chemical composition of nickel-chromium alloy 600 (UNS 066(H)),wt.-%: 76.0 Ni, 15.8 Cr, 7.20 Fe, 0.04 C, 0.20 Mn, 0.10 Cu, 0.04 C, O.tM)7 si. 4. Indicates molybdenum-tipped electrode.



31



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Table 31 Seam Welding Parametersfor Annealed Nickel-Chromium Alloy X7503 on Single-phase Equipment Electrode Wheel Width and Shape'**



Minimum



Contacting Overlap mm (in.) I



Sheet Thickness



W mm (in.) Min.



--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



6.4 (0.25) 0.38 (0.015 ) 6.4 (0.25) 0.53 (0.021) 9.5 (0.37) 0.79 (0.031) 9.5 (0.37) 1.57 (0.062) 12.7 (0.50)



4



I



Net



E mm (in.) Max.



mm (in.)



Electrode Force kN (Ib)



3.2 (0.13) 3.2 (0.13) 5.6 (0.22) 4.8 (0.19) 4.8 (0.19)



76 (3.0) 76 (3.0) 76 (3.0) 76 (3.0) 152 (6.0)



1.8 (400) 3.1 (700) 6.2 (400) 10.2 (2300 17.8 (4000



Radius



Welding On (Pressure Speed Welds pel Current mm/min Time Tight) Meter (APProx-) Amps (in.) Cycles Cycles (in./min) 1 2



3 4 8



Off Time



Weld



3 4 6 8 16



11 4 0 (45) 910 (36) 760 (30) 760(30) 300 (12)



3 m 790 (20) 670 (1 7) 3900 8OOO 550 (1 4) 8 500 470 (12) 10 300 390 (10)



+LI"



B



*



4.8 (0.19) 6.4 (0.25) 7.9 (0.31) 9.5 (0.37) 9.5 (0.37)



General Notes: 1. Electrode material: RWMA Class 2 or Class 3. 2. Class 2 preferred for 0.54,0.38, and 0.53 mm (O.OlO,O.015, and 0.021 in.) thicknesses; for 0.7Y and 1.57 mm (0.031 and 0.062 in.) thicknesses, C1a.s 2 or 3 is suiVdble. 3. Nominal chemical composilion of nickel-chromium alloy X750 (UNS N07750), wt.-%:73.0 Ni, 15.5 Cr, 6.75 Fe, 2.50 Ti, 0.85 Cb, 0.80 Al, 0.70 Mn, 0.05 Cu,0 . 0 4 C , 0.030 Si, 0.007 S .



4.7.6 Weld Schedule Times. Properly set times contribute to high quality resistance welding. The values shown for all times are in cycles based on 60 cycles per second. Some of the time variables discussed below are usually part of the welding schedules, but are not necessarily shown in the tables.



metal indentation, distortion, and a small weld nugget diameter. As the electrode force increases, the resistance values of the workpiece circuit will decrease. Lower resistance values require higher current levels in order to provide proper heating of the faying interface to create a proper weld nugget. Therefore, a correct balance of current, weld time, and electrode force is necessary. Electrode alignment is necessary for proper weld force application. Nonparallel electrode faces can result in a limited electrode tip contact area which will experience a large effective weld pressure. The non-uniform application of weld force may result in excessive surface indentation, 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 topreventweld nugget cracking in resistance seam welding, an intermittent drive is used so that the forging force is applied directly over the intended weld nugget. When an intermittent drive is used, theelectrode wheels are stopped for each weld nugget.



4.7.6.1 Squeeze Time. This time includes allowances for delays in valve shifting, mechanical movement of the weld head to the work, thecomplete 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 continued 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 severalcycles longer than the specified hold time because of mechanical delays.



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Table 34 Spot Welding Parameters for Annealed Nickel on Single-phase Equipment Electrode Diameter and Shape'**



Minimum Contacting Overlap mm (in.)



Sheet Thickness mm (in.)



d in. Max.



D in. Min.



Net Electrode



Force kN (Ib)



Welding Current (APPW Amps



Weld Time Cycles



0.13 (0.005 to: 0.13 (0.005)4.0 (0.16)4.0 (0.16)O.# (1 00) 3 ) (0.16)0.44 (1 00) 0.25 (0.010) 4.0 (0.1 64.0 3 4.0 (0.16)4.0 (0.16)0.49 (110) 3 0.38 (0.015) 0.53 (0.021)4.0 (0.16)4.0 (0.16)0.49(1 1 O) 3 4.0 (0.16)4.8 (0.19)0.49(1 10) 0.78 (0.031) 3 1.6 (0.063) 4.0 (0.16)4.8 (O.1 9) 0.52(1 20) 3 2.4 (0.093) 4.0(O.16) 4.8(O.1 9) 0.52 (1 20) 3 3.2 (0.125) 4.0 (0.16)4.8 (0.19)0.52(1 20) 3 0.25 (0.010) to 0.25 (0.010) 4.8 (0.19)4.8 (0.19)0.58 (130) 3 0.38 (0.015)4.0 (O.16) 4.8 (0.19)0.58 (130) 3 3 0.53 (0.021)4.0 (O.16) 4.8 (O.19) 0.58 (1 30) 4.0 (0.16)4.8(O.19) 0.58 (1 30) 3 0.78 (0.031) 1.6 (0.063) 4.0 (0.16)4.8(0.19) 0.62 (140) 3 2.4 (0.093) 4.0 (0.16)4.8 (0.19)0.62 (140) 3 3.2 (0.125) 4.0 (0.16)4.8 (0.19)0.67 (150) 3 0.38 (0.0 15) to 0.38(0.015) 4.8 (0.19)4.8 (0.19)11.1 (250) 3 0.53 (0.021)4.8 (0.19) 4.8 (O.19) 11.1 (250) 3 4.8 (0.19) 4.8 (O.1 9) 11.1 (250) 3 0.78 (0.031) 1.6 (0.063) 4.8 (0.19)6.4 (0.25) 1.16 (260) 3 3 2.4 (0.093) 4.8(O.19) 16.0 (0.63)l.lh(260) 3 3.2 (0.125) 4.8 (O.1 9) 16.0 (0.63)1.16(260) to: 0.53 (0.021) 0.53 (0.021)4.0 (O.16) 4.0 (O.16) 1.65 (370) 4 4 0.78 (0.031)4.0 (0.16)4.0 (0.16)1 .h5 (370) 1.6 (0.063) 4.0(0. 16)4.0 (O.16) 1.65 (370) 4 2.4 (0.093) 4.0 (O.1 6) 16.0 (0.63)1.69 (380) 4 3.2 (0.125) 4.0(O.16) 16.0 (0.63)1.69 (380) 4 to: 0.78 (0.031) 4.8 (0.19)4.8 (O.19) 4.00(900) 4 0.78 (0.031) 4 1.6 (0.063) 4.8 (0.19)4.8 (O.19) 4.00(900) 2.4 (0.093) 4.8(0.19) 4.8 (0.19)4.00(O) 6 3.2 (0.125) 4.8 (0.19)16.0 (0.63)4.36 (980) 6 to: 1.6 (0.063) 6 1.6 (0.063) 6.4 (0.25)6.4 (0.25) 7.65 (1 720) 3.01 (1800) 8 2.4 (0.093) 6.4(0.25) 6.4 (0.25) 3.01 (1800) 10 3.2 (0.125) 6.4 (0.25)6.4 (0.25) to: 2.4 (0.093) 2.4 (0.093) 7.9 (0.31)7.9 (0.31)3.23 (2300) 12 3.2 (0.125) 7.9 (0.31) 7.9 (0.31)3.23 (2300) 20 to: 3.2 (0.125) 20 3.2 (0.125) 9.5 (0.37) 9.5 (0.37)1.68 (3300)~



7 100 7 400 7 500 7 800 8000 8 100 8 150 8 200



--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---



i



+-ILI+



B &



Minimum Weld Spacing mm (in.)



Nugget Diameter mm (in.)



E



+I



1-D



Shear



Strength kN (Ib)



6.4(0.25: 9.5 (0.37)2.5 (0.10) 0.13 (30) 6.4(0.25) 7.9 (0.31) 2.5 (0.10) 0.16 (36) 6.4 (0.25)7.9 (0.31) 2.5 (0.10) 0.18(40) 6.4 (0.25) L2.7 (0.50) 2.5 (O.10) 0.20 (45) 6.4 (0.25) 12.7 (0.50) 2.5 (0.10) 0.22(SO) 6.4 (0.25)9.5 (0.37) 2.5 (0.10) 0.22 (50) 6.4 (0.25) 16.0 (0.63)2.5 (0.10) 0.22(50) 6.4 (0.25) 0.24 (55) 16.0 (0.63)2.5 (O.10)



11 800 1 1 900 12 o00 12 200 12 300 12 300 12 500



6.4 (0.25) 9.5 (0.37)3.0 (0.12)0.60 (135) 6.4 (0.25) 9.5 (0.37)3.0 (0.12) 0.64 (1 45) 6.4 (0.25)7.9 (0.31)3.0 (O.12) 0.67 (I 50) 6.4 (0.25)7.9 (0.31) 3.0 (0.12)0.71 (160) 6.4 (0.25).2.7(0.50) 3.0 (0.12) 0.82 (1 85) 6.4 (0.25)6.0 (0.63) 3.0 (0.12)0.86 (1 YO) 6.4 (0.25).6.0 (0.63) 3.0 (0.12) 0.93 (210)



12 300 12 500 12 600 12 800 13 O00 13 1 0 0



6.4 (0.25) 7.9 6.4 (0.25) 2.7 6.4 (0.25)2.7 6.4 (0.25) 4.3 6.4 (0.25)6.0 6.4 (0.25)6.0



(0.31)3.0 (O.12) 0.80 (180) (0.50)3.3 (O.13) 1.11 (250) (0.50)3.3 (0.13)1.25 (280) (0.56)3.3 (0.13) 1.33 (300) (0.63)3.3(O.13) 1.56 (350) (0.63) 3.3 (0.13) 1.38 (310)



7.9 7.9 7.9 7.9 7.9



(0.56)3.0 (0.12) 1.47 (330) (0.63) 3.0 (0.12) 1.65 (370) 3.0(O.12) (0.63) 1.76 (400) (0.69)3.0 (0.12) 1.91 (430) (0.75) 3.3 (0.13) 2.00 (450)



7 800 8 200 8600



8 800 YO00



(0.31)4.3 (0.31)6.0 (0.31)6.0 (0.31)7.5 (0.31)9.0



15 400 15 200 13 500 14 200



9.5 (0.37)2.2 (0.87) 4.6 (O.18) 3.38 (760) 9.5 (0.37)2.2 (0.87)4.3 (O.17) 3.43 (770) 9.5 (0.37)5.4 (1 .W) 4.6 (0.18)3.74 (840) 9.5 (0.37) 5.4(1 .00) 4.6 (0.18) 4.14 (930)



21 600 20 o00 21 o00



16.0 16.0 16.0



(0.63)8.1 (1.50)6.4 (0.25)0.78 (2400) (0.63) 1.3 (1.63)6.4 (0.25)1.34 (2550) (0.63)4.5 (1.75)6.4(0.25) 1.79 (2650)



26 400 25400



19.0 19.0



(0.75)7.6 (1.87)7.9 (0.75)0.8 (2.00) 7.9



(0.31)6.01 (0.31)6.46



(3600) (3700)



31 O00



!2.2



(0.87)7.2



(0.37) 4.91



(5600)



(2.25)9.5



General Notes:



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Minimum



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Table 35 Spot Welding Parameters for Nickel-Iron-ChromiumAlloy X' Weld Time Cycles



Sheet Face Thickness Diameter Tip mm (in.) Material mm (in.) Contour



0.76 (0.030) RWMA 6.4 (0.25) Class 3



Flat



1.60 (0.063) RWMA 7.9 (0.31) Class 3



Flat



2.39 (O.OY4) RWMA 9.5 (0.37) Class 2



Flat



Weld Force kN (Ib)



Welding Current (Approx.) Heat Cool Impulses Amps



Forge Force kN (Ib)



4.0 (900) 11.1 (2500)



2



8



18900



2



Average Shear Strength (Ib)



Average Tensile Strength kN (Ib) kN



6.13 (1380) 3.88(872)



10(2500) 2 17.8 (4000) 11.1



9 (4400) 33.4 (7500) 19.6



2



Generdl Note: 1. Nominal chemical cornposition of nickel-iron-chromiumalloy X (UNS NOMX)2),wt.-%: 47.5 Ni, 21.7 Cr, 18.5 Fe, 9.0 Mo, I .5 Co, 0 . 1 C.



Table 36 Seam Welding Parameters for Nickel-Iron-ChromiumAlloy X* Electrode Wheel Face Width' (Flat Face) mm (in.)



Sheet Thickness mm (in.)



0.76 (0.030) 1.60 (0.063) 2.39 (0.094)



Net Electrode Force kN (klb) Weld



4.8 (0.19) 7.9 (0.31)



6.67 (1 SO) 8.90 (2.00)



Weld Time



Forge



Heat Cycles



Cool Cycles



None



10



2



Impulses 1 8



10 2 17.79 (4.00) 20.02 (4.50) 20.0210(4.50) 9.52(0.37)



4



Welding Current (Approx.) Amps



Welding Speed Welds per m (in.)



None



20 250



15 25



21 500



550 (14) 394 (IO)



Forge Cycles



33000



315(8)



General Notes: 1. Electrode material: RWMA Class. 2. Nominal chemical composition of nickel-iron-chromium alloyX (UNS NMK)2), wt.-%:47.5 Ni, 21.7 Cr, 18.5 Fe, 9.0 Mo, 15. Co, 0.1 C.



Table 37 Spot Welding Parametersfor Cobalt-Chromium-Nickel Alloy2



I



Electrode'



Sheet Thickness mm (in.)



Diameter mm (in.)



Tip Contour



0.76 (0.030)



4.8



Flat



(O. 19)



1.(io 7.9 (0.063) (0.31)



Flat



2.39 12.7 (0.094) (0.50)



Flat



General Noles: 1. Electrode material: RWMA Class 3.



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Force kN (Ib)



1



Weld Time



i



Welding



Cool Heat Cycles Cycles



Average Shear Strength (Approx.) Amps kPa (ksi)



1 Current



I



Forge



Average Tensile Strength kPa (ksi)



8.915 13 650 5.65 (1.293) (0.82)



10



0.5



10



2.5



4



20



0.5



8



1



50 200



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Electrodes



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Table 38 Spot Welding Parameters for Various Copper Alloys Alloy Muntz metal High brass Cartridge brass Low brass Red brass Manganese red brass Aluminum bronze Silicon brass Silicon bronze Phosphor bronze Nickel-aluminum bronze Nickel-aluminum bronze (precipitation hardenable)



Weld Time Cycles



Net Electrode Force kN (Ib)



4 4 4 6 6 6 4 6 6 6 6 4



1.78 (400) 1.78 (400) 1.78 (400) 1.78 (400) 1.78 (400) 1.78 (400) 1.78 (400) 2.27 (51O) 1.78 (400) 2.27 (5 10) 1.78 (400) 2.27 (510)



Welding Current Amps 21 o00 21 O00 21 O00 21 o00 21 O00 21 o00 21 o00 21 000 21 o00 21 O00 21 000 21 o00



General Notes: 1. Sheet thickness: 0.91 mm (0.036 in.). 2. Electrode: RWMA Class 1,4.8 mm (0.19 in.)face diameter (flat tip), 30 degrees bevel. Source: Resistance Welding Theory und Use, American Welding Society, Miami, Florida, 1956.



Table 39 Spot Welding Parameters for TitaniumAlloy 6%AI+%V Net



mm (in.)



Weld Electrode Sheet Contacting Welding Nugget Time Force Thickness Current Overlap kN (Ib) Cycles Amps mm (in.) mm (in.)



5 500 7 0.89 (0.035) 2.67 (600) 10 600 10 1.57 (0.062) 6.67 (1500) 12 11 500 1.78 (0.070) 7.56 (1700) 10.68 (2400) 2.3616(0.093) 12 500



12.7 (0.50) 15.9 (0.63) 15.9 (0.63) 19.0 (0.75)



CrossShear Weld Tension Penetration Diameter Strength Strength % k N (Ib) kN (Ib)



8.4 (0.33) -



-



87.3



-



7.65 (1720) 2.67 (600) 22.22 (5000) 4.45 (1OOo) 28.25 (6350) 8.23 (1850) 9.34 (2100) 37.37 (8400)



General Notes: 1. Electrode: RWMA Class 2, 15.9 mm (0.63 in.) dia. shank, 76 mm (3 in.) tip radius. 2. Squeeze time, cycles: 60. 3. Hold time, cycles: 60. Source: "Welding and Process Manual-Titanium," Welding Engineer, April 1967.



4.7.6.4 Heat and Cool Times (Seam Welding).If a slower welding speed is necessary, the cool time should be increased to maintain the same number of welds per mm (in,), thus preventing an excessive heat input which may cause undue distortion of the work. The welds per mm are related to the welding speed, weld time,and cool time as shown by the following formula:



U.S. Customary Units: Welds per in.=



60 x Line Frequency (cycles per second) (Heat Time + Cool Time) x Welding Speed @./min) where the heat andcool times are in cycles and the welding speed is in mm per minute (in. per minute).



SI units: Welds per mm =



4.7.6.5 Off Time. This variable is generally used when the welding cycle is repetitive.



60 x Line Frequency (cycles per second) (Heat Time t Cool Time) x Welding Speed (mm/min)



4.7.7 Weld Current. The values shown in the tables are approximate and are intended to help calculate and 40



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Table 40 Variation of Current Density and Unit Force Due to Lack of Electrode Tip Maintenance ~~



Ï



Area Tip 400% Area Tip SmallToo



Proper



3



Tip Area 56% Too Large



4 Tip Area 1 2 5 % Too Large



~~



5 Tip Area 300% Too Large



W W W



a



&I B



0.079 cm2 (0.0123 in?)



0.317 cmz (0.0491 in?)



0.495 cm2 (0.0767 in.3



(0.1105 in.?



1.267 cmz (0.1964 i n . 3



At Diameter 3.18 mm (0.125 in.)



At Diameter 6.35 (0.250 in.)



At Diameter 7.94 (0.313 in.)



At Diameter 9.52 mm (0.375 in.)



At Diametcr 12.70 mm (0.500 in.)



Unit Force 411 MPa (59 O00 psi)



Unit Force 103 MPa (15 O00 psi)



Unit Force 65 MPd (9 500 psi)



Unit Force 45 MPa ( h 500 psi)



Unit Force 26 MPa (3 710 psi)



0.713 cm2



~~



Current Density 123 690 A/cm2 (798 880



Current Density 31 O00 Ncm2 (200 O00



Result force and current. Severe indentation and Ideal Setup expulsion from high current density.



Current Density 19 810 A/cm2 (127 800



Current Density 13 640 A/cm2 (88 O00



Current Density 7 730 A/cm* (49 900



Result Only 64% of the rcquired force and currcnt.



Result Only 44%of the rcquired force and current.



Result Only 25% of the required force and currcnt.



Weak Spot Weld



Stick Weld



No Weld At All



General Note: 1. Example 2 shows the correct tip size for application requiringa welding force of3250 N (730 Ib) and a welding current of 9800A. Thusa 6.35 mm (0.250 in.) diameter electrode tip will produce a unit force of 103 MPa (1500 psi) and a current density of 31OU A/cm* (2Ol)OOO



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.



4.7.8 Minimum Contacting Overlap.These values indicate the minimum overlapto obtain satisfactory welds. It is important to avoid using overlap below these recommended values; otherwise, expulsion of metal, distortionof the lapping sheets, or edge welds may occur, andthe weld may have low strength and contain porosity and cracking.



4.7.7.1WeldScheduleOptions. Some welding conditions may benefit from weld schedule options. These include preheat, upslope, pulsation, postheat, downslope, and heat steppers. These options adjust the welding current before, during, and after welding. They may be used alone or in combination with one another to provide various benefits such as annealing, tempering, increased tip dressing intervals, longer electrodelife, and reduced power consumption.



4.7.9 Minimum Spot-Weld Spacing. The weld spacings specified are measured from weld center to weld center.Values less than those indicated create increased shunting currents. This condition requires compensation unless other measures are usedto compensate for current shuntings.



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4.7.10 Nugget (Fusion Zone) Diameter or Width. These values may be used to establish nugget diameter (spot welds) or width (seam welds). 41 Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004 11:34:02 MDT Questions or comments about this message: please call the Document Policy Group at 303-397-2295.



STDOAWS C L * L M / C L - L - E N G L 2000



=



4.7.11 Minimum Shear and Tensile Strengths. Tension-shear and cross-tension tests are acceptable methods of checking of spot welds. It should be recognized that variations in individual weld strengths exist. If weld strength is used to determine an acceptable machine setting, it should be above a minimum acceptable value. 4.7.12 Spot Welding Various Thickness Combinations and Arrangements.The weldingparameters used are normally determinedby deciding which of the sheet thicknesses in a particular combination should determine or “govern” the weld schedule. Table 41 shows the guidelines that should generally be followed in setting up welding parameters to join various thickness combinations and arrangements of uncoated and coated carbon and low-alloy steels. In using this table, first refer to the left column, “Metal Combinations and Arrangements,” to identify the applicable metal combination arrangement. Next, select the desired electrode arrangement from across the top of the table, and locate the boxin that column that meets the specific combination. The letters in the boxes refer to the electrode diameters (A and B) and weld schedule to be used in a particular combination. These values are determined by finding the welding parameters recommended for the actualX, Y,Z metal sheet thickness values shown in Tables 1, 2,4, 5 , 6 , 7,9, 10, and 11. Note that these recommended parameters apply only to Set-ups with less than the “Maximum Thickness Ratio” as shownfor each combination, and a change in electrode configuration would be required for ratios greater than these shown. It is also recommended that, for three sheet combinations, the minimum electrode spacing be increased by 30 percent above that normally used for two sheet combinations. 4.8 Weld Discrepancies and Causes.Effective problem solving ortroubleshooting in resistance welding requires a knowledge of weld discrepancies and their causes. Generally, the solution becomes obvious oncethe cause is determined. The acceptability of a discrepancy depends onthe specific application. The following is a general discussion of weld discrepancies and their causes. Causes of spot, seam and projection weld discrepancies can be divided into welding equipment related and process-application related: (1) Welding-Equipment Related: (a) Welding machine: o Improper machine type o Improper kVA rating o Inadequate rangeof adjustment of current or force o Improper fixture design o Excessive friction or inertia in the movable ram



Electrode tip skidding Transformer saturation Broken leads of primaryand secondary electrical circuits Excessive oxide build-up on contact surfaces of secondary circuit Line voltage variations Inadequate power supply cooling Machine mechanical and electrical repeatability (b) Electrode: Deformed or worn electrodes thatreduce the current density at theelectrode-to-workinterface Poor maintenance or misalignment Incorrect face shape or geometry Incorrect alloy Inadequate water cooling (c) Welding Control: Incomplete f u n c t i o m n e or more of the following may be required: pulsation, preheat, forge, quench, temper, current downslope, or current upslope. Repeatability Improper settings (2) Process Application Related: (a) Joint Configuration Poor part fit-up Poor part design Inadequate joint overlap Poor joint accessibility (b) Surface Condition: Poor or inconsistent surface finish Contaminated surfaces High electrical resistance coatingon surfaces to be welded (c) Shunting of the welding current: Through previous welds Through the part itself Through fixturing or tooling (d) Weld Parameters: Incorrect welding process Improper welding schedule Improper projection size or location Attempting to weld too many widely spaced projections at once The following are various problems thatoccur in spot, seam and projection welding, and their possible causes. It is assumed that the machine is functioning properly and that the metalto be welded is resistance weldable. (I) Expulsion or Porosity at Weld Interface: o Contaminated surfaces (drawing compoundor paint) o Poor part fit-up o Inadequate joint overlap o Electrode force too low 0 Weld current too high



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AWS C l .1 M/C1.1:2000



AWS Cl .1 MIC1.1:2000



Table 41 Spot Welding Parameters for Various Thickness Combinations and Arrangements of Uncoated and Coated-Carbon and Low-Alloy Steels Electrode Arrangement2.3*



Metal Thickness Combinations TipTip Dia. Dia. and A Arrangements'



X X=Y



3



2



1



Max. B



Thick Weld Schedule Ratio



x



x



Y+10%



x



x



Y+10% X/Y=1/4



x



x



X+10%



x



-



Y X X