Tool- Resistance Welding Troubleshooting Guide

8/12/2019 Tool- Resistance Welding Troubleshooting Guide

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Overheating of Weldment Discoloration Weak Weld Metal Expulsion Sparking

60

INSTR!TIONS"

!#SE

Excess Current/Energy

Insufficient Current/Enery

Excess Time

Insufficient Time

Insufficient Squeeze Time

Insufficient Hold Time

$#SI! TRO$%ES&OOTIN' R%ES" (In order of )riorit*+ Insufficient Upslope

Excess Force

Insufficient Force

oor !eld"e#d Follo$%up

!rong ol#rity

oor ro&ection 'esign

Exercise consistent process control o(er m#teri#ls) equipment #nd t"e $eld process*oor l#ting of or +xidized 'irty #rts

Incomp#ti,le -et#ls.equires Co(er #s

#rts -is%positioned

!rong Electrode -#teri#l

'irty Electrodes

Electrode Tip S"#pe

Follo$ instructions #,o(e to determine ,est course of #ction* -us"roomed Electrodes

Try simplest solutions/#d&ustments first*

C"#nge only one (#ri#,le #t # time*

InsufficientNugget

us" t"e ,uttons for t"e S-T+- +. .+12E-* 'etermine most li3ely C4USE#nd S+2UTI+5 ,#sed on .I+.IT num,ers $it" #s "ig"est priority* St#rttrou,les"ooting $it" #nd t"en proceed to 7 #nd so on* In c#ses $"ere t"ere #remultiple c#uses $it" t"e s#me priority) use t"e follo$ing sequence fortrou,les"ooting8 -4TE.I42 .E24TE') E2ECT.+'E .E24TE') !E2'HE4'.E24TE') +!E. SU2 .E24TE'*

)OWER S))%,RE%#TED

9erify correct equipment set%up #nd line (olt#ge: insure #ll c#,le #nd ot"er electric#lconnections #re tig"t: repl#ce ,ro3en flexures* WE%D&E#D

RE%#TED

Use cle#n electrodes #nd m#teri#ls* Insure electrode #lignment $it" f#ces p#r#llel to

M#TERI#%RE%#TED

'ress electrodes regul#rly #nd consist#ntly using 600 grit p#per or polis"ing dis3 ;nofiles<*

4s # gener#l st#rting point) use s"ortest time) "ig"est re#son#,le force #nd #$eld"e#d $it" f#st follo$%up #nd lo$ m#ss electrode "olders*

E%E!TRODERE%#TED





Electrode Damage

)RIORIT, SO%TIONS

7 'ecre#se current in steps of >%0@

0 Incre#se current in steps of >%0@

7 'ecre#se $eld time in steps of >%0@ ;5/4 for C'<

0 Incre#se $eld t ime in steps of >%0@ ;5/4 for C'<

0 Incre#se squeeze time in steps of 70 milliseconds ; cycle for 4C<

0 Incre#se "old time in steps of 70 milliseconds ; cycle for 4C<

0 Incre#se upslope time in steps of > milliseconds ;5/4 for C' #nd 4C<

0 'ecre#se force in steps of 0%70@

Incre#se force in steps of 0%70@

= Use $eld"e#d $it" f#st follo$%up #nd/or reduce m#ss of top electrode "older*

7 .e(erse pol#rity of e#c" electrode

0 Cont#ct Unite3 Equipment 4pplic#tions 2#, for #ssist#nce

Cle#n p#rts ,efore $elding* C"ec3 pl#ting t"ic3ness #nd comp#ti,ility*

0 C"#nge one met#l or use t"ird interf#ce met#l0 Use #rgon or simil#r co(er g#s*

0 ro(ide tooling/f ixtures to "old p#rts in pl#ce*

C"ec3 Electrode/-#teri#l Selection uide*

7 Cle#n electrodes #nd/or p#rts to ,e $elded*

Use const#nt #re# electrodes or s"#pe to suit #pplic#tion*

0 .epl#ce or res"#pe electrodes or incre#se cle#ning sc"edule*

InconsistentWelds

ElectrodeSticking



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Tool- Resistance Welding Troubleshooting Guide