ResistanceWelding電阻焊

1、Resistance Welding Reference Manual2Section 1 provides an introduction to the following resistance welding topics:Section 1: Introduction3Figure 1-01 Current Wave Formation Comparison電流電流電容器放電型電容器放電型晶體管放電型晶體管放電型變頻器放電型變頻器放電型交流電放電型交流電放電型時間時間各種電流波形的對比4Figure 1-02 Basic Resistance Welding Process受力方向受力方

2、向受力方向受力方向材料焊接面材料焊接面下電極下電極上電極上電極電流方向電流方向電阻在受到電流通過時電阻在受到電流通過時快速發(fā)生發(fā)熱使段面融化快速發(fā)生發(fā)熱使段面融化5Section 2: Performance ObjectivesTerminal Objective Given the resistance welding training material, you will be able to identify and explain general resistance welding principles and concepts to help improve the weldin

3、g quality of various resistance-welded products. 6Section 2: Performance ObjectivesEnabling ObjectivesDiscuss resistance welding safety.Identify resistance welding equipment and explain its operation.Identify resistance welding materials and components, and discuss projections, plating, and disc wel

4、ding issues.Explain the weld process, and discuss the parameters associated with the process.Identify resistance welding electrodes and discuss electrode selection.Describe resistance welding equipment maintenance.Explain resistance welding testing and failure analysis.Troubleshoot resistance weldin

5、g problems.7Section 3: Resistance Welding Terms and DefinitionsThis section provides various terms and definitions associated with resistance welding.8Section 4: General Resistance Welding SafetyUpon completion of this section, you will be able to discuss general resistance welding safety.Welding eq

6、uipment familiarization熟悉焊接設(shè)備Electrical shock觸電General resistance welding equipment safety guidelines普通焊接機(jī)的安全指導(dǎo)方針9Figure 4-01 Typical Body Resistances and Currents10Section 5: Resistance Welding EquipmentUpon completion of this section, you will be able to identify resistance welding equipment and e

7、xplain its operation.11Figure 5-01 Simplified Electrical System of a Resistance Welding Machine中心變壓器中心變壓器等級開關(guān)等級開關(guān)初級變壓初級變壓二級變壓二級變壓易曲連接帶易曲連接帶連接臂連接臂12Figure 5-02 Typical Weld Head13Figure 5-03 Basic Transformer14Figure 5-04 Single-Impulse Resistance Spot Welding Schedule15Figure 5-05 Various Current Wa

8、ve Formations16Figure 5-06 Complex Weld Cycle焊前間焊前間隙隙擠壓時間擠壓時間預(yù)焊時間預(yù)焊時間焊接時間焊接時間焊后間隙焊后間隙保持時間保持時間回火時間回火時間淬火時間淬火時間17Figure 5-07 Typical Air Cylinder Components活塞瓣活塞瓣密封圈密封圈軸軸18Section 6: Resistance Welding Materials and ComponentsUpon completion of this section, you will be able to identify resistance wel

9、ding materials and components, and discuss projections, plating, and disc welding issues.19Figure 6-01 Simple Projection Weld20Figure 6-02 Various Types of Projection Welds21Section 7: Resistance Weld Process and ParametersUpon completion of this section, you will be able to explain resistance weld

10、process and discuss the parameters associated with the process.22Figure 7-01 Single Weld Cycle23Figure 7-02 Normal Weld Cycle24Figure 7-03 Weld Cycle/Upslope/Quench Temper25Figure 7-04 Example Parameter Card26Figure 7-05 Welding Current with Upslope and Downslope Features27Figure 7-06 Electrode Desi

11、gned for Welding Wire28Figure 7-07 Phase Shift Associated with Percent (%) Heat Adjustment29Figure 7-08 Current and Pressure Relationship on Nugget Formation30Figure 7-09 Effect of Current and Time on Temperature Deviation31Figure 7-10 Simplified Electrical System of a Resistance Welding Machine32Fi

12、gure 7-11 Effects on Current Requirements by Changing Areain a Current Loop33Figure 7-12 Effect of Poor Electrode Follow-up On the Weld Cycle34Figure 7-13 Follow-up Force35Figure 7-14 Weld Head Related Problems36Figure 7-15 Weld Strength Profile37Figure 7-16 Single-Impulse Resistance Spot Welding Sc

13、hedule38Section 8: Electrode IdentificationUpon completion of this section, you will be able to identify resistance welding electrodes and discuss electrode selection.39Figure 8-01 Heat Input to Electrode傳導(dǎo)方向傳導(dǎo)方向受力方向受力方向40Figure 8-02 Effect of Electrode Mushrooming on Weld41Figure 8-03 Different Sha

14、pe Types of Electrodes42Figure 8-04 Electrode Shape That Should Be Avoided 43Figure 8-05 Press-Fitted Tungsten Tip and Chrome CopperElectrode Arrangement44Figure 8-06 Weld Splash45Figure 8-07 Typical Double-Acting Air Cylinder Arrangement46Figure 8-08 Heat Generated in a Typical Weld47Section 9: Res

15、istance Welding Equipment MaintenanceUpon completion of this section, you will be able to describe resistance welding equipment maintenance.48Figure 9-01 Example of a Maintenance Control Cycle49Section 10: Resistance Welding Testing and Failure AnalysisUpon completion of this section, you will be able to explain resistance welding testing and failure analysis.50Figure 10-01 Potential Weld Failures51Figure 10-02 P