Spot welding parameters

Spot welding parameters include:

Electrode force Diameter of the electrode contact surface Squeeze time Weld time Hold time Weld current

The determination of appropriate welding parameters for spot welding is a very complex issue ! small change of one parameter will effect all the other parameters This" and the fact that the contact surface of the electrode is gradually increasing" ma#es it difficult to design a welding parameter ta$le" which shows the optimum welding parameters for different circumstances However" this ta$le shows target values for the welding parameters
Sheet thickness, t [mm] Electrode force, F Weld current, I [kN] [A] Weld time Hold time Electrode diameter, d [cycles] [cycles] [mm]

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Electrode force
The purpose of the electrode force is to squeeze the metal sheets to $e 0oined together This requires a large electrode force $ecause else the weld quality will not $e good enough However" the force must not $e to large as it might cause other pro$lems When the electrode force is increased the heat energy will decrease This means that the higher electrode force requires a higher weld current When weld current $ecomes to high spatter will occur $etween electrodes and sheets This will cause the electrodes to get stuc# to the sheet !n adequate target value for the electrode force is /% 1 per mm) 2ne pro$lem" though" is that the size of the contact surface will increase during welding To #eep the same conditions during the hole welding process" the electrode force needs to $e gradually increased !s it is rather difficult to change the electrode force in the same rate as the electrodes are 3mushroomed3" usually an average value is chosen

Diameter of the electrode contact surface

2ne general criterion of resistance spot4welding is that the weld shall have a nugget diameter of +5t,6)" 7t8 $eing the thic#ness of the steel sheet Thus" a spot weld made in two sheets" each , mm in thic#ness" would generate a nugget + mm in diameter according to the +5t94rule Diameter of the electrode contact surface should $e slightly larger than the nugget diameter :or example" spot welding two sheets of , mm thic#ness would require an electrode with a contact diameter of & mm ;n practice" an electrode with a contact diameter of & mm is standard for sheet thic#ness of % + to , )+ mm This contact diameter of & mm conforms to the ;S2 standard for new electrodes

Squeeze time
Squeeze Time is the time interval $etween the initial application of the electrode force on the wor# and the first application of current Squeeze time is necessary to delay the weld current until the electrode force has attained the desired level

Weld time
Weld time is the time during which welding current is applied to the metal sheets The weld time is measured and ad0usted in cycles of line voltage as are all timing functions 2ne cycle is ,6+% of a second in a +% Hz power system <When the weld time is ta#en from !merican literature" the num$er of cycles has to $e reduced due to the higher frequency <&%Hz= that is used in the >S! =

!s the weld time is" more or less" related to what is required for the weld spot" it is difficult to give an exact value of the optimum weld time :or instance:

Weld time should $e as short as possi$le The weld current should give the $est weld quality as possi$le The weld parameters should $e chosen to give as little wearing of the electrodes as possi$le <2ften this means a short weld time = The weld time shall cause the nugget diameter to $e $ig when welding thic# sheets The weld time might have to $e ad0usted to fit the welding equipment in case it does not fulfil the requirements for the weld current and the electrode force <This means that a longer weld time may $e needed = The weld time shall cause the indentation due to the electrode to $e as small as possi$le <This is achieved $y using a short weld time = The weld time shall $e ad0usted to welding with automatic tip4dressing" where the size of the electrode contact surface can $e #ept at a constant value <This means a shorter welding time =

When welding sheets with a thic#ness greater than ) mm it might $e appropriate to divide the weld time into a num$er of impulses to avoid the heat energy to increase This method will give good4loo#ing spot welds $ut the strength of the weld might $e poor ?y multiplying the thic#ness of the sheet $y ten" a good target value for the weld time can $e reached When welding two sheets with the thic#ness , mm each" an appropriate weld time is ,% periods <+%Hz=

Hold time (cooling-time)

Hold time is the time" after the welding" when the electrodes are still applied to the sheet to chill the weld @onsidered from a welding technical point of view" the hold time is the most interesting welding parameter Hold time is necessary to allow the weld nugget to solidify $efore releasing the welded parts" $ut it must not $e to long as this may cause the heat in the weld spot to spread to the electrode and heat it The electrode will then get more exposed to wear :urther" if the hold time is to long and the car$on content of the material is high <more than % ,A=" there is a ris# the weld will $ecome $rittle When welding galvanized car$on steel a longer hold time is recommended

Weld current

The weld current is the current in the welding circuit during the ma#ing of a weld The amount of weld current is controlled $y two thingsB first" the setting of the transformer tap switch determines the maximum amount of weld current availa$leB second the percent of current control determines the percent of the availa$le current to $e used for ma#ing the weld Cow percent current settings are not normally recommended as this may impair the quality of the weld !d0ust the tap switch so that proper welding current can $e o$tained with the percent current set $etween seventy and ninety percent The weld current should $e #ept as low as possi$le When determining the current to $e used" the current is gradually increased until weld spatter occurs $etween the metal sheets This indicates that the correct weld current has $een reached