Golden Eagle Resistance Welding Training

Module 3 Energy & Time

Major Resistance Welding Variables

Materials

Energy

Good Weld
Time

Weld Force

Resistance Welding Technologies:

High Frequency Inverter (HF) Linear DC Capacitor Discharge (CD) Direct Energy (A.C.)

High Frequency Inverter

1 - 25 kHz

Power Supply
Feedback

Welding Transformer

Weld Head

High Frequency Attributes

Single Pulse
Characteristics: Energy control in Current, Voltage, or Power Time control in 0.1 millisecond increments (minimum) High Repetition Rates Closed Loop Feedback Compensates for varying part conditions Built-in Monitor Applications and Use: Best control for automation. Extends electrode life. Can weld a wide range of applications.

Upslope/Downslope

Dual Pulse

Linear DC
Power Supply Weld Head
Drive Unit
Capacitor Charging Circuit

Feedback

Voltage Leads

Cap Bank

MOSFET Bank

Current Shunt

Linear DC Attributes
Single Pulse
Characteristics: Energy control in Current, Voltage, or Power Time control in 0.01 millisecond increments (minimum) Low Repetition Rates Closed Loop Feedback Compensates for varying part conditions Built-in Monitor Applications and Use: Ultra stable waveform. Extends electrode life. Best choice for welding fine wires and thin foils.

Upslope/Downslope

Dual Pulse

Capacitor Discharge
Power Supply
SCR Circuit

Pulse Transformer

Weld Head

Capacitor Charging Circuit

Cap Bank

Capacitor Discharge Attributes

Single Pulse
Characteristics: Energy control in % Energy or Watt-Seconds Time control in Pulse Widths Low Repetition Rates Open Loop - No Feedback Lacks true upslope control

Dual Pulse
Applications and Use: Fast rise time with high peak current. Good for welding flat conductive parts. Require good part fit up.

Pulse Width Adjustment

Direct Energy
Power Supply Welding Transformer
Taps

Triac

Weld Head

Timer

Direct Energy Attributes

Transformer Taps
I%
Characteristics: Coarse energy control with transformer taps Fine energy control in % Current Time control in Line Cycles High Repetition Rates Open Loop - No Feedback Susceptible to Line Voltage Fluctuations Weld cools between cycles Applications and Use: General purpose, lower cost welders with high energy output. Longer weld times useful for brazing applications.

% Current Control

Cycle Welding

Capability vs. Optimal Range

TYPICAL MATERIALS:
Resistive: Molybdenum, Tungsten, Zinc, Nickel, Platinum, Tin, Tantalum, Steel, Titanium, MP35N, Nichrome
Size of Smaller Part (Diameter)

Conductive: Silver, Copper, Gold, Aluminum, Brass

ROUND PART SIZES

.0002 .005 mm
Optimal

.018 0.46 mm

.036 0.91 mm

.054 1.37 mm

.072 1.83 mm

.090 2.29 mm

DC HF

Optimal Optimal Optimal Optimal

CD AC
.001 .025 mm Size of Smaller Part (Thickness) .010 0.25 mm

Optimal Optimal Optimal

.020 0.51 mm

.030 0.76 mm

.040 1.02 mm

.050 1.27 mm

FLAT PART SIZES

Specification Comparison
Closed Loop: DC HF
Input Power Output Range Feedback Modes Feedback Rate Weld Monitoring Time Control in: Repetition Rate Equipment Cost Application and Use Notes 115V; 230V Single Phase 5-4000 Amps I, V, & P >10 micro-sec Built-in I, V, & P .01 msec steps 240V; 400V; 480V Three Phase 50-4000 Amps I, V, & P 40-250 micro-sec Built-in & Sentry 0.1 msec steps

Open Loop: CD AC
115V; 230V Single Phase Up to 875 WS N/A (Open Loop) N/A (Open Loop) Sentry Option Pulse Widths 115V; 230V; 460V Single Phase Up to 16 KVA N/A (Open Loop) N/A (Open Loop) Sentry Option Line Cycles

Fine energy control, smooth waveform. Best choice for welding fine wires & foils.

Best automation supply. Extends electrode life. Welds wide range of applications.

Fast rise time with high peak current. Good for welding conductive parts.

General purpose control with high energy output. Longer weld times useful for brazing.

Closed Loop Power Supply Fit

AMPS 4000

HF2
2400 CURRENT

DC25 HF25 UB25

1000

10 msec

50 msec

TIME

100 msec

Why Choose Closed Loop?

Repeatable Welds Controlled Heating Rate Feedback Modes Built In Monitoring Process Tools Longer Electrode Life

Repeatable Welds
A Closed Loop power supply will keep the programmed parameter constant (Current, Voltage, or Power). It will adjust the non programmed parameter to achieve the programmed value to compensate for changes in part or process conditions.

Weld 1

Weld 2

Weld 1 Weld 2

Constant Current Weld Pulses

Output Voltage Waveforms

A Real World Example

Two sequential welds were made on production parts. The same current was delivered, but the voltage adapted to the difference in work piece resistance.

Weld 1:

Weld 2:

Controlled Heating Rate (Upslope)

At the beginning of the weld, contact resistance is high. Using open loop power supplies without controlled upslope can result in: Expulsion Electrode Sticking Excessive Marking Weak Welds

RC1

RC2
RC3

Controlled Heating Rate (Upslope)

If too much energy is applied before the electrodes have a chance to seat properly, energy will be wasted at the electrode to part contact area.

Heat Affected Zone

Feedback Modes
Constant Voltage:
Compensates for parts misplacement and force problems Reduces weld splash Ideal for round (non-flat) parts Monitor current Varies current and voltage for consistent energy Breaks up surface oxides and plating Ideal for automation to extend electrode life Monitor current or voltage Delivers same current regardless of resistance changes Compensates for part thickness changes Ideal for flat parts with consistent electrode to part fit-up Monitor voltage

Constant Power:

Constant Current:

Part and Process Challenges:

Parts: Surface Roughness Plating Inconsistencies Oxidized Parts Contamination Projections Wire Welds Thickness Inconsistencies Process: Part Misplacement Varying Overlap Inconsistent Force Mushroomed Electrodes Oxidized Electrodes Automated Systems Weld Cables

Part Challenges:
Surface Roughness Plating Inconsistencies Oxidized Parts Contamination Projections Wire Welds Thickness Inconsistencies

Constant Power

Constant Voltage

Constant Current

Process Challenges:
Part Misplacement Varying Overlap Inconsistent Force Mushroomed Electrodes Oxidized Electrodes Automated Systems Weld Cables

Constant Voltage

Constant Power

Current, Voltage, or Power

Feedback Modes
Feedback Mode Part Challenges
Constant Voltage Projections Wire Welds

Process Challenges
Part Misplacement Varying Overlap Inconsistent Force Mushroomed Electrodes Oxidized Electrodes Automated Systems

Constant Power

Surface Roughness Plating Inconsistencies Oxidized Parts Contamination Constant Current Flat Parts, Thickness Inconsistencies

Weld Cables

Weld Monitoring
Graphic waveform traces (HF25, DC25, UB25) provide: Simple, dynamic weld information for process understanding and diagnostics Easy set limits with programmable relay action Other process tools Pre-Weld Check A.P.C. Resistance Set Weld to Limit Energy Limit

Process Tools
Pre Weld Check

Active Part Conditioner / Resistance Set

Weld to a Limit

Energy Limit

Process Tools
Note: Welding conductive parts with resistive electrodes may be difficult to monitor electrically.

In these applications, the bulk resistance of the electrodes is much greater than the resistance of the parts. Displacement monitoring is preferred.

Statistical Process Control

Some monitors offer RS-232 or RS-485 transmission of weld data to a P.C.
Identify Process Trends Record Keeping

Quality Reporting
S.P.C. software packages can generate control charts and provide data summaries