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Lecture 5a - Practical Session - Welding Practice and Tests

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Candice Chita
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7 views8 pages

Lecture 5a - Practical Session - Welding Practice and Tests

Uploaded by

Candice Chita
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Renewable Energy

CHMT4032A: Advanced Chemical Engineering-

Hybrid Fuel Cell & Advanced Technologies

Prof S Iyuke

- 5-Day Adv Chem Eng Course -

July 2022

1 Hybrid-Renewable Energy Training Course.


CHMT 4032A Welding Practice & Tests
Opposed Welding – Resistance
Spot Welding (RSW) utilizes
two electrodes positioned
exactly opposite and in line with
each other (electrodes share a
common axis). Each electrode
contacts a single piece of base
material. Each weld cycle
produces only one fused spot.
Series Welding – RSW utilizes two electrodes positioned adjacent to each other but
separated by an air gap or other dielectric. Each electrode contacts the same
surface of base material. This type of welding is utilized where access to both sides
of the weld joint is physically restricted or if a component damage would result if the
welding current were to shunt through the system circuit or electrical component.
Support tooling opposing the force of the electrodes is insulated from the welding
circuit and therefore does not shunt current from the welding circuit. Each weld cycle
produces two fused spots. The electrodes can be positioned parallel or at a fixed
angle to each other.

2 Hybrid-Renewable Energy Training Course.


Destructive Peel Testing

+ The edges of a spot


welded sample
connection shall be
gripped and pulled
apart to failure.

+ The welded connection (lap joint) shall be pulled in tension at


an approximate 900 angle to the plane of the faying joint
surfaces.
+ The length of the grip sections on the samples shall be long
enough to preclude any interference of the gripping
hardware with the welded connection.

3 Hybrid-Renewable Energy Training Course.


Destructive Peel Testing, Cont.

+ The result of the peel test must be a plug pull-out in a minimum of 75% of
the total number of individual spots in the sample set for connections with
4 or more spots, 85% for connections with 3 spots and 100% for
connections with 2 or less spots.
+ individual samples from the 15 peel tests fail to result in at least 2 plug
pull-outs from the total number of weld spots on the individual
connection, 2 additional welded sample connections may be welded and
submitted for inspection and testing as part of the initial sample set, one
time only.
+ These 2 samples shall then be factored into the above acceptance
criteria.
+ If more than 2 samples from the original lot fail the peel test as described
above, further weld parameter development or process analysis to
determine the cause for the failure(s) is required prior to submitting
another 16 samples for testing to the requirements of this specification.

4 Hybrid-Renewable Energy Training Course.


Peel Test of Nickel Tab on Battery
Bimetallic Tab

+ If the minimum plug pull-out requirement for the total number of


individual spots in the sample set (i.e., 75%, 85%, or 100% for the
respective condition) can not be met as described above, further
weld parameter development or process analysis to determine the
cause for the failure is required prior to submitting another lot of
samples for testing to the requirements of this specification.

5 Hybrid-Renewable Energy Training Course.


Topographic Image of Plug 1 from Positive
Cap 1710

6 Hybrid-Renewable Energy Training Course.


Visual Inspection of RSW

All welds shall be inspected visually


at a magnification of 30X. The welds
shall conform to the following visual
inspection criteria [2 marks each]:

a. Cracked Weld - Any weld that


exhibits a crack in the weld zone
shall be rejected.

b. Pitted/Deformed Weld - Any weld that exhibits pits, holes or voids open
to the surface, in either of the materials being shall be rejected. Surface
deformation or upset from electrode contact shall not be considered
unless the area in question exhibits sharp notch like characteristics,
severe oxidation due to overheating, or where either of the elements has
been deformed/upset by more than 50% of the material thickness.
7 Hybrid-Renewable Energy Training Course.
Visual Inspection of RSW, Cont.

c. Metal Expulsion - Any weld that exhibits metal expulsion where the
molten metal has become separated from the weld area shall be
rejected.

d. Electrode Deposit - Significant deposits of the electrode tip being left


on the weld surface shall be rejected. Topical shallow deposits and
superficial marks shall not be considered.

e. Open Weld - An open weld shall be rejected. An open weld is one in


which a weld has been attempted but no bonding has occurred.

f. Missed Weld - Any weld that has been specified on the drawings but
has been overlooked by the welding operator shall be identified and
welded to meet the drawing requirements.

8 Hybrid-Renewable Energy Training Course.

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