Welding Technology
1-Day Course
Learn the processes and equipment used in resistance (spot) welding. You will review: basic resistance welding, how welds are made, components and mechanics of a welding system, pneumatic and hydraulic systems, testing methods and weld schedules for various materials and coatings.
WHO SHOULD ATTEND:
All types of Engineers, Product Designers, Tool and Die Makers and anyone interested in an overall understanding of resistance welding.
COURSE OUTLINE:
| 1.0 | How a Weld is Made |
| 1.1 Resistance Spot Welding | |
| 1.2 Characteristics of the Weld Nugget | |
| 1.3 Making a Spot Weld | |
| 1.4 Relationship of the Welding Variables | |
| 1.5 The Elementary Welding System | |
| 2.0 | Welding Fixture Secondary Components |
| 2.1 Introduction | |
| 2.2 In-line Weld Gun Assembly | |
| 2.3 Welding Electrodes (caps) | |
| 2.4 Electrode Holder Assembly | |
| 2.5 Threaded Adapters | |
| 2.6 Tapered Shank Cap Adapters (Barrels) | |
| 2.7 Offset Electrode Caps and Adapters | |
| 2.8 Water Tubes and Water Tube Adapters | |
| 2.9 In-line Welding Gun Cylinders | |
| 2.10 Stationary Back-up Electrodes | |
| 2.11 Secondary conductors (shunts) | |
| 2.12 Welding Fixture Transformers | |
| 2.13 Weld Circuit and Power Considerations | |
| 2.14 Primary Circuit Power Control | |
| 3.0 | Secondary System Mechanical Arrangement |
| 3.1 Positioning and Holding Production Parts | |
| 3.2 Magnetic Losses | |
| 3.3 Electrical Switches | |
| 3.4 Water Distribution | |
| 3.5 Fixture Color Codes | |
| 4.0 | Multiple Welding Secondary |
| 4.1 Weld Power Supply | |
| 4.2 Weld Loop Impedance | |
| 4.3 Types of Resistance Welding | |
| 4.4 Balanced Welding Conditions | |
| 4.5 Classes of Welds | |
| 5.0 | Portable and Robot Spot Welding |
| 5.1 Portable Weld Guns | |
| 5.2 Portable Weld Gun Designs | |
| 5.3 Transformer Secondary Cables | |
| 5.4 Portable Welder Suspension Systems | |
| 5.5 Robot Integral Weld Guns | |
| 5.6 Color Coding of Components | |
| 5.7 Weld Gun Assembly | |
| 5.8 Portable and Robot Welding Standards | |
| 6.0 | Weld Schedules, Metals and Other Variables |
| 6.1 Resistance Spot Welding | |
| 6.2 Basic Welding Circuit | |
| 6.3 Weld Sequence | |
| 6.4 Welding Variables | |
| 6.5 Protective Coatings | |
| 6.6 Contaminants on the Metal | |
| 6.7 Composition of Metal (Metallurgy) | |
| 6.8 Weld Heat Balance | |
| 6.9 Metals Commonly Resistance Spot Welded | |
| 6.10 Multiple Thickness Welds | |
| 6.11 Spot Spacing | |
| 6.12 Weld Schedules | |
| 7.0 | Weld Quality and Testing Methods |
| 7.1 Spot Weld Defects | |
| 7.2 Corrective Action for Eliminating Spot Weld Defects | |
| 7.3 Welding Equipment Testing and Troubleshooting | |
| 7.4 Secondary System Maintenance | |
| 7.5 General Maintenance |
