A weld schedule is a set of parameters used to control the welding process in resistance welding. These parameters include the welding current, welding time, electrode force, and electrode size. A well-designed weld schedule is critical to achieving a high-quality, repeatable weld. Here are the steps to create a weld schedule for resistance welding:
Determine the Material Properties
The first step in creating a weld schedule is to determine the properties of the materials being welded. This includes the type of metal, its thickness, and its electrical resistance. This information is necessary to select the appropriate welding current, welding time, and electrode force. Reference the RWMA reference welding manual for a baseline.
Select the Welding Current
The welding current is the amount of electrical current that is passed through the metal during the welding process. The welding current is selected based on the thickness and electrical resistance of the materials being welded. Generally, the thicker the material, the higher the welding current required. The welding current is also affected by the type of metal being welded.
Determine the Welding Time
The welding time is the amount of time that the welding current is applied to the metal. The welding time is determined by the thickness of the materials being welded, the welding current, and the desired strength of the weld. A longer welding time may be required for thicker materials or for materials that require a stronger weld.
Select the Electrode Force
The electrode force is the amount of force applied to the metal during the welding process. The electrode force is selected based on the thickness and hardness of the materials being welded. Generally, the harder the material, the higher the electrode force required.
Determine the Electrode Size
The electrode size is the size of the electrodes that are used to apply the electrode force to the metal. The electrode size is selected based on the surface area of the weld and the desired penetration depth. A larger electrode size may be required for a larger surface area or for materials that require deeper penetration.
Test the Weld Schedule
Once the weld schedule has been created, it is important to test the welds to ensure that they meet the desired strength and quality. It is hard to determin the quality of the welds by visually inspecting the welds only. Performing destructive testing bsuch as a pushout tester, or using non-destructive testing methods such as a force senser or weld current monitors.
In conclusion, creating a weld schedule for resistance welding requires a thorough understanding of the materials being welded and the welding process. By following the steps outlined above, you can create a well-designed weld schedule that will produce high-quality, repeatable welds. Don't forget! It is important to test the welds to ensure that they meet the desired strength and quality.
More questions? Please consult with one of our resistance welding experts to determine the best solution for your specific application.