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Electrodes and Tooling. Lesson Objectives When you finish this lesson you will understand: The various electrode materials and design Electrode and part.

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Presentation on theme: "Electrodes and Tooling. Lesson Objectives When you finish this lesson you will understand: The various electrode materials and design Electrode and part."— Presentation transcript:

1 Electrodes and Tooling

2 Lesson Objectives When you finish this lesson you will understand: The various electrode materials and design Electrode and part holders and fixtures Typical Applications Learning Activities 1.View Slides; 2.Read Notes, 3.Listen to lecture 4.Do on-line workbook 5.Do Homework Keywords Resistance Welding Electrodes, RWMA Classification, Electrode Geometry, Multiple Welding Tools, Fixtures

3 Electrode Functions Conduct the welding current to the work Transmit the proper electrode pressure or force to the work in order to produce a satisfactory weld Help dissipate heat from the weld zone

4 RWMA Electrode Material Standards Group A - Copper Base Alloys –RWMA Class 1 Zirconium Copper Cadmium Copper Chromium Copper –RWMA Class 2 Chromium-Zirconium Copper Chromium Copper –RWMA Class 3 Cobalt-Beryllium Copper Nickel-Beryllium Copper Beryllium-Free Copper –RWMA Class 4 Beryllium Copper –RWMA Class 5 Aluminum Copper

5 RWMA Electrode Material Standards (CONT.) Group B - Refractory Metals and Refractory Metal Composites –RWMA Class 10 Copper Tungsten –RWMA Class 11 Copper Tungsten –RWMA Class 12 Copper Tungsten –RWMA Class 13 Tungsten –RWMA Class 14 Molybdenum Group C - Specialty Material –RWMA Class 20 Dispersion- Strengthened Copper

6 Electrode Materials RWMA Class # Electrical Conductivity Composition (%) Ultimate Strength (ksi) Annealing Temperature (°C) Thermal Conductivity (Cal/cm-sec-°C) Cu 99-Cu, 1-Cd 99.2-Cu, 0.8-Cr 97-Cu, 2.5- Co, 0.5-Be Cu & Be Cu & Al (C) 82 (F) 48 (C) 52 (F) 20 (C) 23 (F) (F) 30 (C) 62 (F) 95 (C) 105 (F) 110 (C) 170 (F) (C) 0.75 (F) 0.43 (C) 0.45 (F) 0.18 (C) 0.19 (F) 930 (C) 900 (F) 1020 (C) 900 (F) * C = Cast, F = Forging

7 Typical Hardness-Temperature Curves [Reference: Resistance Welding Manual, p.18-2, RWMA]

8 Electrode Geometry “A” 6° 20° 45° ° Pointed Dome Truncated Cone Truncated Cone [Reference: Welding in the Automotive Industry, p.135, D. W. Dickinson]

9 Electrode Size Net Electrode Force (lb x 10 2 ) Electrode Face Diameters (inch) Electrode Body Diameters (inch) [Reference: Resistance Welding Manual, p.18-14, RWMA]

10 Spot Welding Electrode Nose Geometries [Reference: Resistance Welding Manual, p.18-15, RWMA] Type “A” Type “B” Type “C” Type “D” Type “E” Type “F” Pointed Dome Flat Offset Truncated Radius

11 W. Stanley, Resistance Welding McGraw-Hill, 1950

12 W. Stanley, Resistance Welding McGraw-Hill, 1950

13 Interchangeable Die Set (a) (b) (c) [Reference: Resistance Welding Manual, p.17-6, RWMA] (b)

14 Tooling for Multiple Welding Stud and Jam Nuts Equalizing Bar Split and Clamped to Electrode Flexible Conductors Slip-Fit Lower Electrode Welding Pressure Adjustment Screw Compression Spring Flexible Conductors Slip-Fit Workpiece (a)(b) [Reference: Resistance Welding Manual, p.17-8, RWMA]

15

16 Tooling for Multiple Welding (CONT.) [Reference: Resistance Welding Manual, p.17-8, RWMA] (a) (b)

17 Tooling for Multiple Welding (CONT.) (a) (b) [Reference: Resistance Welding Manual, p.17-9, RWMA]

18 Press Welding Machine Fixtures [Reference: Resistance Welding Manual, p.17-11, RWMA]

19 Workholding Devices: Dial Mechanisms [Reference: Resistance Welding Manual, p.17-11, RWMA]

20 Workholding Devices: Shuttle Devices (a) (b) [Reference: Resistance Welding Manual, p.17-12, RWMA]

21 Workholding Devices: Conveyor Type Fixtures [Reference: Resistance Welding Manual, p.17-13, RWMA]

22 Electrodes


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