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WJM TechnologiesExcellence In Material Joining
Small-Scale Resistance Welding for Medical and Industrial
ApplicationsGirish P. Kelkar, Ph.D.
(author of “The Weld Nugget”)
WJM Technologieshttp://www.welding-consultant.com/
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WJM Technologiesexcellence in material joining
Difference Between Small and Large Scale
Small-Scale – size, power, equipment Materials Types of Bonds Weld Configurations Process Control
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WJM Technologiesexcellence in material joining
Small-Scale Physical Size: < 0.010” diameter, <0.005” thick Current: <5 kA Force: <30 lbs Time: <100 msec Often need microscope for welding
Smallest Weld 0.0008” (20 micron) thermocouple cross-wire weld 20 amps, 0.5 lbs, and 1.5 msec
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WJM Technologiesexcellence in material joining
Small-Scale Power supply is often a single unit
that includes controller and transformer and built-in weld monitors
HF: High Frequency (1-25 kHz) DC: Direct Current CD: Capacitor Discharge AC: Alternating Current
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WJM Technologiesexcellence in material joining
Materials Conductive alloys: Cu, Au, Pt, Ag Structural alloys: Steel, SS, Ni, Ti Refractory alloys: Mo, W, Ta
Welding of dissimilar material combinations Molybdenum to Aluminum Tungsten to Iron Copper to Stainless Steel
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WJM Technologiesexcellence in material joining
Types of Bonds Fusion weld is not common in small-scale
resistance welding: Fusion welds (10%) Solid-State Welds (60%) Solder (10%) Braze (20%)
Include in-situ braze: one of the parts itself acts like a braze alloy
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WJM Technologiesexcellence in material joining
Braze (foil)
BAg-1 braze foil Copper plated SS wire to SS shell
Tube
Wire
Braze
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WJM Technologiesexcellence in material joining
Braze (in-situ)
Steel foils sandwiching a Mo wire
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Solid-State Bond
Commutator welds common in motor industry
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WJM Technologiesexcellence in material joining
Solid-State Bond
Fusing stranded wire before welding
ShoesElectrodes
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WJM Technologiesexcellence in material joining
Weld Configuration
Parallel gap weld and step welds are common since access for opposed welding is not often
available
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WJM Technologiesexcellence in material joining
Weld Configuration Single Weld designs are common
Each weld has to be good since supporting welds are often not possible
Need good process control and monitoring
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WJM Technologiesexcellence in material joining
Process Control Voltage, Current, and Power Pulsed Welding Resistance Conditioning Combo Mode
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WJM Technologiesexcellence in material joining
Voltage Control
Inconsistent Overlap Weld will draw current based on amount of overlap Reduced overlap or less number of coils will result in
reduced current
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Power Control
Power control generates fixed amount of heat Works well for parts with multiple orientations
Consolidated Wire Bundle
High RLow I and High V
Low RHigh I and Low V
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WJM Technologiesexcellence in material joining
Pulsation
Pulsation allows the user to increase the proportion of heat generated at the interfaces
Time
Contact Resistance
Bulk Resistance
Res
ista
nce
Weld Energy
Time
Contact Resistance
Bulk Resistance
Res
ista
nce
Weld Impulses
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WJM Technologiesexcellence in material joining
Pulsation
Welding of Nickel Wire in single and multiple (4) pulses Single impulse exhibits excessive material squeezed out Multiple impulse weld produced considerably less material squeeze out
Single Pulse Multiple (4) Pulse
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WJM Technologiesexcellence in material joining
Resistance Conditioning
Variable first pulse (time) to control resistance Second pulse to provide weld energy Good for parts with inconsistent cross section or
variable oxide thickness
Voltage or Power ModeCurrent Cut-Off
First Pulse Second Pulse
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WJM Technologiesexcellence in material joining
Combo Mode
Initial part in voltage mode (to avoid blowouts) Second part in current or power mode for welding
Voltage or Power Mode
Current Mode
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WJM Technologiesexcellence in material joining
Summary Small-Scale welding applications are unique in
terms of size, application, type of bond, and process control needs
Key is to understand bond formation and design process accordingly
Process control is important for robust welding and consistent quality