T.O. 1-1A-9
TABLE 4-29. SPOT WELDING WITH 3-PHASE FREQ CONVERTER MACHINES - SINGLE WELD FORCE .
ALLOY
SHEET
LOW FREQ
CYCLES
ELECTRODE
APPROX RMS
ELECTDE
THICKNESS
PULSE
WELD
WELD FORCE
CURRENT
DOME
(IN.)
(LBS)
AMPS
RADIUS
AZ31B
0.063
3
½
1750-3400
35200-67900
4"
HK31A
0.040
1
½
1000-1800
19600-27900
3"
0.063
3
½
2400-3600
39400-53800
4"
0.125
5
3
5000 (min)
65900 (min)
6"
HM21A
0.040
1
1
800-1600
21600-30300
3"'
0.083
3
1
1600-2800
40600-53800
4"
0.125
5
1
3800 (min)
66700 (min)
6"
TABLE 4-30. SPOT WELDING AZ31B, ELECTROSTATIC STORED ENERGY MACHINES
1/ - SINGLE WELD FORCE.
SINGLE SHEET
ELECTRODE WELD
CONDENSER CAPA
CONDENSER
DOME TIP
THICKNESS
FORCE (LBS)
(MICROFARADS)
VOLTAGE
RADIUS
(INCHES)
(INCHES)
0.020
600-800
240
1400-1800
2-4
0.040
900-1100
600
2200-2600
2-4
0.063
1300-1600
1080
2000-2400
2-6
0.080
2000-2400
1400
2000-2400
4-6
0.100
2600-3000
1800
2000-2400
4-6
0.125
3500-4000
2280
2000-2400
4-6
1/ Time to peak 10-20 milliseconds; turns Ratio 480:1.
TABLE 4-31. SPOT WELD FAULTS.
FAULT
CAUSE
CORRECTION
Explusion
Insufficient weld pressure. Welding current
Increase pressure. Decrease
too high partially cleaned surface. Electrode
current. Clean material
radius too small.
thoroughly. Use proper
electrode.
Cracking and
Dirty Surfaces
Make trial welds to determine -
Porosity
Wrong pressure & hold time
proper settings. Penetrate
should not be less than
20% nor more than 80% into
each of the parts welded
Indentation
Electrode tip contour.
Use flat tip on outside surfaces -
or gauges up to 0.063".
On heavier gauges use flat
tips on both surfaces.
Pick-Up
Inadequate surface cleaning
Clean thoroughly.
Electrode tips not cleaned frequently enough.
Clean frequently.
Improper cooling and condensation
Intermittent cooling during
welding only.
Polarity effect of IC equipment.
4-39/(4-40Blank)
