1、V on _ Res i s t an ce - Edited by B. J. Bastian, P.E. O 1998 by American Welding Society. All rights reserved Printed in the United States of America American Welding Society 550 N.W. LeJeune Road, Miami, Florida 33 126 NOTE: Although care was taken in choosing and presenting the data in this guide
2、, AWS cannot guarantee that it is error free. Further, this guide is not intended to be an exhaustive treatment of the topic and therefore may not include all available information, including with respect to safety and health issues. By publishing this guide, AWS does not insure anyone using the inf
3、ormation it contains against any liability of injury to property or persons arising from that use. 2 Table of Contents Basic Safety Precautions 4 Chapter I-Definitions 5 Resistance Welding . 5 Spot Welding 11 Seam Welding . 12 Projection Welding . 12 Flash Welding . . 12 Chapter 2-Resistance Welding
4、 Electrodes 15 Chapter 3-Spot and Seam Welding Parameters . 17 Chapter they are rather starting conditions for setting up welding schedules to be followed in any particular welded fabrication. They may be modified accordingly to obtain optimum conditions for the specific conditions and production re
5、quirements. 17 Table 2-Spot Welding Parameters for Low-Carbon Steel Net Welding Minimum Minimum Minimum Nugget Dia. in. Metal Electrode* Electrode Weld Current Contact Weld Shear Thickness Face Dia. Force Time (APPWX.) Overlap Spacing Strength* Minimum in. in. Ib. Cycles Amps in. in. lb. Satisfactor
6、y Set-up 0.020 0.025 0.030 0.035 0.040 0.045 0.050 0.055 0.060 0.070 0.080 0.090 0.105 o. 120 0.188 0.188 0.250 0.250 0.250 0.250 0.312 0.312 0.3 i 2 0.312 0.312 0.375 0.375 0.375 400 450 500 600 700 750 800 900 1 O00 1200 1400 1600 1800 2100 7 8 9 9 10 11 12 13 14 i6 18 20 23 26 8500 9500 10500 115
7、00 12500 13000 13500 14000 i 5000 16000 17000 18000 19500 21000 0.44 0.47 0.5 1 0.53 0.56 0.59 0.61 0.63 0.65 0.68 0.72 0.78 0.84 1 .o2 0.38 0.50 0.62 0.75 0.85 0.94 1 .o0 1 .O6 1.12 i .25 1.44 1.56 i .68 1.81 3 20 450 550 750 925 1150 1350 1600 1850 2300 2700 3450 4150 5000 0.12 0.12 0.14 0.16 0.18
8、 0.19 0.20 0.21 0.23 0.25 0.26 0.27 0.28 0.30 - o. I 80 o. 180 0.250 0.250 0.250 0.250 0.312 0.312 0.3 12 0.312 0.312 0.375 0.375 0.375 *Shapes that can be used are: E =Truncated Cone (45 o Bevel) A =Pointed B =Domed F =RadiusTip Also see Figure I. Notes: 1. For intermediate thicknesses, force, weid
9、 time, and current may be interpolated. 2. Electrode material: RWMA Class 2. 3. Minimum weld spacing is measured from centerline to centerline. 4. The data within this table was supplied by committee members and represents an average of typical parameters used in industry. 5. Based on single-phase A
10、C 60 (Hz) equipment. 6. *Based on 30 psi yield strength material. 18 Table 3-Pulsation Spot Welding Parameters for Low-Carbon Steel Electrode Diameter and Shape 10“ r-=i%m Min. d = 1/4” Combination of Net Thicknesses D” “d” Electrode to be Welded Min. Max. Force in. in. in. Ib. Weld Time On 20 off5
11、Cycles Cycles Number of Positions Nugget Dia. Adjacent Welds Minimum Minimum in. Current Contact Shear Single 1 in. to 2 in. to Approx. Overlap Strength* Minimum Welds 2in. 4in. Amps in. in. Satisfactory Set-up 0.125 to0.125 I .o0 0.44 I800 3 5 4 18000 0.88 5000 0.38 0.45 0.125 to O. 188 1 .o0 0.44
12、1800 3 5 4 I8000 0.88 5000 0.38 0.45 O. 125 to 0.250 I .o0 0.44 I800 3 5 4 18000 0.88 5000 0.38 0.45 0.188to0.188 1.25 0.50 1950 6 20 14 19500 1.12 Imo 0.50 0.60 O. 188 to 0.250 1.25 0.50 1950 6 20 14 19500 1.12 lo000 0.50 0.60 0.188 to0.312 1.25 0.50 1950 6 20 14 19500 1.12 loo00 0.50 0.60 0.250 to
13、 0.250 1.25 0.56 2150 12 24 18 21500 1.38 15000 0.56 0.70 0.250 to 0.3 I2 I .25 0.56 2150 12 24 18 21500 1.38 15000 0.56 0.70 0.312 to 0.312 1 SO 0.62 2400 15 30 23 24000 1 SO 20000 0.62 0.70 Notes: I. Type of steel-Y.S. less than 70 ksi. 2. Electrode material: RWMA Class 2. 3. For the 3-in. radius
14、face electrodes, the face diameter is the same as the electrode diameter. 4. Based on single-phase AC 60 (Hz) equipment. 5. *Based on material with less than 70,000 psi tensile strength. 6. Adjacent welds are measured as to distance between spots. 19 Table 4-Spot Welding Parameters for Low-Alloy and
15、 Medium-Carbon Steels Electrode ic ”-1 $!k+ Material Net Temper Satis- ”D” “d” “R” Electrode Weld Current Min. Min. Min. factory Min. Face Face Weldand Weld Quench Temper Current %of Contacting Weld Shear Nugget Thickness Dia. Dia. Radius Temper Time Tune Time (Appmx.) Weld Overlap Spacing Strength
16、Dia. SAE 1020 Hot Rolled 0.040 518 114 6 1475 6 17 6 16000 YO 1/2 1 1360 0.23 6 20 6 14200 Y1 I 12 1 1560 0.22 SAE 1035 Hot Rolled 0.040 5/8 114 6 1475 SAE 1045 HotRolled 0.040 5/8 1/4 6 1475 6 24 6 13800 88 1 /2 1 2000 0.21 SAE4130 HutRoIled 0.040 518 1/4 6 1475 6 18 6 13000 90 1 12 1 2120 0.22 SAE
17、4340 N test the sample in a normal peel test; examine the weld area for cracks. If any are present, the material is “hold time sensitive.” 5. Based on single-phase AC 60 (Hz) equipment. 25 Table 10-Spot Welding Parameters for HSLA Steel (ASTM Grade A568) (Max. Y.S.-55 ksi) Electrode, Nugget Dia. in.
18、 Flat Face Net Minimum Minimum Minimum Thickness Face Dia. Force Time Current Overlap Spacing Strength Minimum Metal (Truncated Tip) Electrode Weld Welding Contact Weld Shear in. in. Ib. Cycles Amps in. in. Ib. Satkactory Set-ur 0.020 0.18 450 8 5500 0.44 0.38 0.024 0.18 530 8 6100 0.47 0.50 0.030 0
19、.25 640 9 6900 0.5 I 0.62 0.036 0.25 700 10 7700 0.53 0.75 0.043 0.25 830 11 8700 0.58 0.90 0.053 0.31 1 000 13 10000 0.62 1 .O3 0.064 0.3 1 1200 17 11500 0.66 1.18 0.077 0.3 I 1430 21 12100 0.70 1.37 0.093 0.35 1730 27 13000 0.80 1.60 0.113 0.35 2100 37 14200 0.93 1.75 0.137 0.35 2500 48 15600 1.25
20、 2.00 Notes: I. Electrode material: RWMA Class 2. 2. Based on single-phase AC 60 (Hz) equipment. 3. Minimum weld spacing is measured from centerline to centerline. 450 0.12 o. 180 500 0.12 0. 180 750 0.14 0.250 1100 0.18 0.250 1300 0.19 0.250 1525 0.2 1 0.312 2600 0.24 0.3 12 3200 0.26 0.312 3800 0.
21、28 0.350 5000 0.3 1 0.350 6250 0.34 0.350 26 Table 11-Spot Welding Parameters for HSLA Steel (SAE 51392) Net Welding Minimum Minimum Minimum Nugget Dia. in. Metal Electrode* Electrode Weld Current Contact Weld Shear Thickness Face Dia Force Time (Approx.) Overlap Spacing Strength Minimum in. in. I b
22、. Cycles Amps in. in. Ib. Satisfactory Set-up Grades O50 and 060 0.020 0.18 450 8 5600 0.44 0.38 475 0.12 o. I80 0.024 0.18 530 8 6300 0.47 0.50 525 0.12 0.180 0.030 0.25 640 9 7000 0.5 I 0.62 770 0.12 0.250 0.036 . 0.25 700 10 8100 0.53 0.75 1085 0.18 0.250 0.043 0.25 830 Il 8900 0.58 0.90 I295 0.1
23、8 0.250 0.053 0.3 i I O00 13 lo000 0.62 I .O4 1610 0.18 0.3 12 0.064 0.31 I200 17 11100 0.66 1.17 2490 0.18 0.312 0.077 0.3 I 1430 21 12100 0.7 i i .38 3230 0.22 0.3 12 0.093 0.35 I730 28 I3300 0.79 1.58 3890 0.22 0.350 0.113 0.35 2100 38 14500 0.93 I .74 5140 0.25 0.350 O. i 37 0.35 2500 51 15700 1
24、.17 i .96 5950 0.25 0.350 Grades 070 and 080 0.020 0.18 450 8 5500 0.44 0.38 525 0.12 0.180 0.024 0.18 0.030 0.18 0.036 0.25 0.043 0.25 0.053 0.25 0.064 0.25 0.077 0.3 1 0.093 0.31 0.113 0.35 O. I37 0.35 E =Truncated Cone (45“ Bevel) A =Pointed Also see Figure 1. *Shapes that can be used are: 530 64
25、0 700 830 1000 1200 1430 1730 2100 2500 8 6500 0.47 0.50 9 7000 0.5 1 0.62 10 7900 0.53 0.75 11 9000 0.58 0.90 13 9900 0.62 I .O4 17 10700 0.66 1.17 21 11800 0.7 1 I .38 28 12500 0.79 I .58 38 13400 0.93 1.74 51 14300 1.17 1.96 Notes: I. Data is based on single-phase AC 60 (Hz) equipment. 2. Minimum weld spacing is measured from centerline to centerline. 3. Electrode material: RWMA Class 2. 650 990 1395 1665 2070 3290 4130 5040 6600 7600 0.12 o. 180 0.12 O. I80 0.18 0.250 0.18 0.250 0.18 0.250 0.18 0.312 0.22 0.312 0.22 0.312 0.25 0.350 0.25 0.350 27
