DOCSLIB.ORG

Ip-215A and Ip-217A Fine Spot Welding Power Supplies

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
Ip-215A and Ip-217A Fine Spot Welding Power Supplies User's Manual 993-603 Revision A: October, 1996 IP-215A AND IP-217A FINE SPOT WELDING POWER SUPPLIES Model Definition IP-215A Standard 50 Amp Power Supply IP-215A/RS485 50 Amp Power Supply With RS-485 Data Port IP-217A Standard 200 Amp Power Supply IP-217A/RS485 200 Amp Power Supply With RS-485 Data Port WARNING: Please be sure to read all personnel and equipment safety precautions noted in this manual. Copyright © 1996 Unitek Miyachi Corporation All Rights Reserved Prepared by Unitek Miyachi Corporation 1820 South Myrtle Avenue Monrovia, CA 91017-7133 Phone (818) 303-5676 FAX (818) 358-8048 TWX (910) 585-1836 IP-215A and IP-217A Fine Spot Welding Power Supplies User's Manual 993-603, October 1996, Revision A Unitek Miyachi Corporation 1820 South Myrtle Avenue Monrovia, CA 91017-7133 Phone (818) 303-5676 FAX (818) 358-8048 TWX (910) 585-1836 ©1996, Unitek Miyachi Corporation The engineering designs, drawings and data contained herein are the proprietary work of UNITEK MIYACHI CORPORATION and may not be reproduced, copied, exhibited or otherwise used without the written authorization of UNITEK MIYACHI CORPORATION. Printed in the United States of America REVISION RECORD Revision EO Date Basis of Revision A 16785 10/96 Not applicable IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 i CAUTIONS AND WARNINGS HIGH VOLTAGE IS USED IN THE OPERATION OF THIS EQUIPMENT DEATH ON CONTACT MAY RESULT IF PERSONNEL FAIL TO OBSERVE THE SAFETY PRE- CAUTIONS LABELED ON THE EQUIPMENT AND NOTED ON THIS PAGE Only a qualified technician should be allowed to work inside the unit. Never work on electronic equipment unless there is another person nearby who is familiar with the operation and hazards on the equipment and who is competent in administering first aid. The technician who is aided by operators must warn them about the hazards. Whenever possible, shut off the power supply to the equipment before beginning work on it. When you have shut off power, ground all parts. Be sure to discharge every capacitor that may hold a dangerous potential to ground when working inside the equipment. Do not touch high-voltage connections or 208/230 volt input connections when installing or operating the equipment. WARNING: Do not be misled by the term low voltage. Potentials as low as 50 volts may cause death under adverse conditions. PLEASE READ THE SAFETY STEPS ON THE NEXT PAGE IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES iv 993-603 REV A: October, 1996 5 SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICAL SHOCK: 1. Do not try to pull or grab the victim. 2. If possible, turn off the electrical power. 3. If you cannot turn off the electrical power, pull, push or lift the victim to safety using a dry wooden pole, a dry rope, or some other non-conductive material. 4. Send for medical help as soon as possible. 5. When the victim is free of contact with the source of electrical shock, move the victim away and start artificial resuscitation. IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 v CONTENTS CHAPTER 1 ABOUT THIS MANUAL Organization.......................................................... 1-1 Referencing Conventions ................................................ 1-2 Related Manuals ...................................................... 1-2 How Are We Doing?................................................... 1-2 If You Need Assistance................................................ 1-3 CHAPTER 2 ABOUT YOUR EQUIPMENT Overview............................................................ 2-1 Performance Features................................................... 2-1 Welding Schedules............................................... 2-2 Welding Monitors ............................................... 2-2 Welding Parameters.............................................. 2-2 Weld Data Storage............................................... 2-2 Automation Capability ............................................ 2-2 Equipment Description ................................................. 2-2 CHAPTER 3 GETTING STARTED Space Requirements .................................................... 3-1 Standard Installation ................................................... 3-1 Making a Trial Weld ................................................... 3-3 CHAPTER 4 CONTROLS Rear Panel Components ................................................. 4-1 Front Panel Components ................................................ 4-2 Display........................................................ 4-2 Control Mode Status Indicators..................................... 4-4 System Status Indicators .......................................... 4-4 Weld Program Key Field.......................................... 4-4 Weld Control Key Field........................................... 4-8 Welcard Drive ................................................. 4-10 POWER Circuit Breaker......................................... 4-10 IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES vi 993-603 REV A: October, 1996 CONTENTS (continued) CHAPTER 5 OPERATING YOUR POWER SUPPLY Display Screen Data Editing ............................................. 5-1 Setting the Weld Schedule............................................... 5-3 Monitoring Power Supply Operation ....................................... 5-4 Monitoring Weld Heat Limits...................................... 5-4 Weld Current................................................... 5-4 Current Setting Monitor (IP-217A Only) ............................. 5-6 Monitoring Average Pulse Width ................................... 5-6 Automatic Performance Monitors................................... 5-7 Selecting the Welding Transformer (217 Power Supply Only) ................... 5-8 Selecting the Weld Count ............................................... 5-9 Setting Control Feedback Gain ........................................... 5-9 Activating the Data Output Port ......................................... 5-10 CHAPTER 6 USING THE WELCARD Care and Treatment of the Welcard........................................ 6-1 Welcard Data Records.................................................. 6-2 Installing the Welcard .................................................. 6-2 Operating With the Welcard ............................................. 6-2 Initializing the Welcard ........................................... 6-2 Referencing the Directory......................................... 6-3 Copying a Schedule to a Welcard ................................... 6-4 Copying a Schedule to the Power Supply ............................. 6-5 Welcard System Error Messages.......................................... 6-6 CHAPTER 7 IN CASE OF DIFFICULTY General Kinds of Problems .............................................. 7-1 Electrode Maintenance ................................................. 7-1 Adjusting Display Viewing Angle......................................... 7-2 Memory Backup Battery Replacement ..................................... 7-2 Technical Assistance................................................... 7-3 IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 vii CONTENTS (continued) APPENDICES A Technical Specifications ......................................... A-1 B Cable Wiring and Signal Specifications ..............................B-1 C Welding Transformer Specifications.................................C-1 D Resistance Welding Basics ....................................... D-1 E Alarm Message List..............................................E-1 F Weld Programming Sheets ........................................F-1 ALPHANUMERIC SUBJECT INDEX READER COMMENT SHEET WARRANTY ILLUSTRATIONS 2-1 IP-215A Fine Spot Welding Power Supply ............................ 2-1 2-2 Using the Power Supply With Multiple Welding Transformers ............ 2-3 3-1 Standard Connection Diagram...................................... 3-2 3-2 System Interconnections for Multiple Welding Transformers ............. 3-3 4-1 Rear Panel Components ........................................... 4-1 4-2 Front Panel Controls and Display ................................... 4-3 6-1 The Welcard Data Storage System .................................. 6-1 7-1 Factory Adjusted Display Viewing.................................. 7-2 7-2 Memory Backup Battery Location .................................. 7-3 TABLES 5-1 Display Data Entry Ranges ..................................... 5-2 6-1 Welcard Error Messages ........................................ 6-6 IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES vi 993-603 REV A: October, 1996 CHAPTER 1 ABOUT THIS MANUAL This manual is organized to assist you in getting productive quickly with the IP-215A or IP- 217A High Frequency Inverter Welding Power Supply. The simplified information and instructions in Chapters 1 through 3 will allow you to get the equipment up and running safely and efficiently, and make basic welds. Chapter 4 explains the operation of the controls and the display. Chapter 5 and the appendices deal with more advanced welding consider- ations and procedures. NOTE: Where the data in this manual is specific to either the IP-215A or the IP-217A, the data is noted as such. All other data is relevant to both the IP- 215A and the IP-217A. Organization This chapter lets you know how to use this manual effectively. The manual contains many tools to help you find and understand information. The physical, electrical and performance specifications are listed in Appendix
Load more

Recommended publications
  • Spot Welding Protocol
    USAFA-TR-2013-05 Contractor Report SPOT WELDING PROTOCOL DIVAKAR MANTHA SAFE INC. 3290 HAMAL CIRCLE MONUMENT, CO 80132-9729 APRIL 2013 Center for Aircraft Structural Life Extension (CAStLE) Department of Engineering Mechanics DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited DEAN OF THE FACULTY UNITED STATES AIR FORCE ACADEMY COLORADO 80840 ii Contents Contents ......................................................................................................................................... iii List of Figures ................................................................................................................................ iv 1. Introduction to Spot Welding of dcPD Probe Wires .................................................................. 1 2. Spot-Welding Stage .................................................................................................................... 1 3. Spot Welding Procedure ............................................................................................................ 3 4. Step-wise spot-welding Procedure .............................................................................................. 8 5. Troubleshooting .......................................................................................................................... 9 iii List of Figures Figure 1: Spot welding stage showing various components of welding ......................................... 1 Figure 2: Connection point for negative terminal of spot welder power
    [Show full text]
  • INSTRUCTION MANUAL for Maintenance
    Document No.: TCI-0003E-M-ACU Control Dept: Electrical Engineering INSTRUCTION MANUAL for Maintenance WELD CONTROL FOR STATIONALY SPOT WELDER NWC-900 series Original instructions ~%:::;::/:;;~J-'(::;~:::::•·-:'-::%~;'(::;~:::;~/:;;~:::;'(::;~~;:/:;;W..J-':'-::%:::;/'-::%::::::..~'}'(::;~;::v:::,~::::;::~~~;,'(::;~;·/'-::%:::;::~'}:/'-::%::::::-:/'~~ ij The instruction manual must be carefully ~ ~.< read for proper machine operation. ~:· »~ «» <~ No person is allowed to install, conduct test run of, operate, maintain, repair the ~< >,' machine or do similar works, without having well understood what the manual refers >~ ~ ~- ~ >,· The improper operation with inadequate knowledge may cause serious accident. >" ~~ Incidentally, the manual must be kept at a place accessible to any of the person ~ ~ concerned. ~ ~ » ~~ Please inquire an uncertain point of our Sales Department/each office. ~~ S:~~~-~;:::-~:;;:v.~:~~~:;:.-0Y~,~1:;;?:(~~~~~,;::::~~~~v~~~~~~Y~-::::~Y~~):!Y~-~ lmJ DENGENSHA 1-23-1 Masugata, Tama-ku, Kawasaki-shi, Kanagawa-ken, JAPAN TEL : +81-44-922-1121 /FAX : +81-44-922-11 00 NOTICE 1. Please do not reprint contents of this instruction partially without permission. 2. The content of Instruction manuals might change without notifying beforehand. 3. Please contact us when there are any suggestions like an uncertain by any chance point, mistake, and description leakage, etc. Revision history - 2010/ 3 Change signal name Nakano ( '11. 1.01 l 12/29 ·~ '~" ~l \..~/ Change Temper cool cycle 2010/ ~a Ochiai- 2 Nozaki 2010/ 2010/ Change Program sheet 09/21 09/22 09/22 2010/ Fukuta Ochiai I Parts code is added to fuse. T.Nakano 2010/ 2010/ 08/31 08/31 08/31 2010/ Fukuta Ochiai - First edition M.Arima 2010/ 2010/ 08/18 08/18 08/18 Revision code Revision item Date Drawn Verification Approved B DENGENSHA Instruction manuals Instruction manuals are provided individually for the welder (Installation, operation, maintenance), program box, monitor box and Special function.
    [Show full text]
  • Welding Technology Certificate of Achievement
    348 • Laney College Catalog • 2019-2020 WELDING TECHNOLOGY (WELD) WELDING TECHNOLOGY CERTIFICATE OF ACHIEVEMENT (CA) Welding Technology (WELD) Welding Technology ofers an opportunity to learn cognitive and manipulative welding skills which prepare the student for employment in occupations that use welding applications. Career Opportunities: Welding is a lead skill in many construction and manufacturing industries, including industrial maintenance, petroleum, cross-country gas transmission, fabrication of goods and equipment, aerospace, food manufacturing, and biotec. Job titles include both manual welders and welding support personnel, including ironworkers, pile drivers, mill wrights, fabricators, welding supplies and equipment sales, weld inspection and weld engineers. COURSE SEQUENCE Core Courses (15 units): Select three courses from the following (9 units): MACH 205 Engineering Drawings for Machinists, 3 WELD 203B Intermediate Gas Tungsten Arc Welding 3 Welders and Industrial Maintenance WELD 203C Advanced Gas Tungsten Arc Welding 3 Technician WELD 204B Wire Feed Welding 3 WELD 203A Beginning Gas Tungsten Arc Welding 3 WELD 211B Arc Welding II 3 WELD 204A Wire Feed Welding 3 WELD 221A Beginning Oxygen-Acetylene Welding 3 WELD 205 Introduction to Welding 3 WELD 211A Arc Welding I 3 TOTAL MAJOR UNITS: 24 Recommended: MATH 202 PROGRAM LEARNING OUTCOMES Upon completion of this program a student will be able to: • Students will recognize the value of wearing safety glasses in the lab by: 1) describing the dangers to the eyes in the welding lab, (such as UV rays, projectiles, chemicals and sparks/molten material); 2) complying consistently with the Department policy of always wearing safety glasses in the lab. • Students will determine several advantages and disadvantages of a given welding process, and diferentiate between diferent welding processes.
    [Show full text]
  • Chapter 074 Volume 1 Welding and Allied Processes
    S9086-CH-STM-010/CH-074R4 REVISION 4 NAVAL SHIPS’ TECHNICAL MANUAL CHAPTER 074 - VOLUME 1 WELDING AND ALLIED PROCESSES THIS CHAPTER SUPERSEDES CHAPTER 074 VOLUME 1, DATED 31 JULY 1998 DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS; ADMINISTRATIVE AND OPERATIONAL USE (31 JANUARY 1992). OTHER REQUESTS FOR THIS DOCUMENT WILL BE REFERRED TO THE NAVAL SEA SYSTEMS COMMAND (SEA-03M2). WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C., SEC. 2751, ET SEQ.) OR EXECUTIVE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH PROVISIONS OF OPNAVINST 5510.161, REFERENCE (JJ). DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO- SURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT. PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND. 23 AUG 1999 TITLE-1 @@FIpgtype@@TITLE@@!FIpgtype@@ S9086-CH-STM-010/CH-074R4 Certification Sheet TITLE-2 S9086-CH-STM-010/CH-074R4 TABLE OF CONTENTS Chapter/Paragraph Page 074 VOLUME 1 WELDING AND ALLIED PROCESSES ...................... 74-1 SECTION 1 INTRODUCTION .................................... 74-1 074-1.1 GENERAL ......................................... 74-1 074-1.1.1 SCOPE. ...................................... 74-1 074-1.1.2 MANDATORY REFERENCING. ........................ 74-1 074-1.1.3 NUCLEAR AND COMBAT WEAPONS SYSTEMS. ............. 74-1 074-1.1.4 SHIP STRUCTURE AND SYSTEMS. ..................... 74-1 074-1.1.5 RESPONSIBILITY FOR COMPLIANCE. ................... 74-1 074-1.1.6 REQUIREMENTS. ................................ 74-1 074-1.2 WELD CATEGORIES ................................... 74-2 074-1.3 REFERENCE DOCUMENTS ............................... 74-2 074-1.3.1 GENERAL.
    [Show full text]
  • RESISTORS for WELDING POWER SUPPLIES - Application Note
    Fixed Resistors RESISTORS FOR WELDING POWER SUPPLIES - Application Note Power and Surge Resistors Welding power supplies require robust power resistors for a range these functions. This Application Note discusses the use of resistors of functions which all share a common requirement; the dissipation in different types of welding power supply circuit and presents a of high power for a limited duration. It is necessary to understand selection of suitable products. the short term overload and surge capability of resistors selected for Applications • Capacitor discharge • Snubbing • Inrush limiting • MOSFET gate drive Resistor Products • Planar thick film • Heatsink mountable • Surge rated SMD TT electronics companies Fixed Resistors RESISTORS FOR WELDING POWER SUPPLIES - Application Note 1. Capacitor Discharge Resistor The MIG arc welding power source shown has a secondary tapped basis of the permissible output ripple voltage. To estimate the ripple, transformer. It consists of a transformer, rectifier and output capacitor. consider that the capacitor supplies the maximum output current I The transformer should have separate primary and secondary continuously, and is charged up to the output voltage every 1/100 s windings so that the output is isolated from the power-line ground. for a fullwave rectifier (50Hz line frequency). The charge Q drawn by The transformer primary to secondary turn ratio determines the the load is I/100s and equals CΔV, where ΔV is the peak to peak amount by which the output voltage is stepped down. The rectifier output ripple voltage. Thus, C = I/100ΔV. The calculations result in is a full wave bridge of silicon diodes that converts the AC output large values of C typically a few 100,000 μF and the designs voltage to DC and an output filter smoothes the secondary voltage are implemented using large aluminium electrolytic capacitors.
    [Show full text]
  • Fine Spot Welder IPB-5000B-MU DC Inverter Welding Power Supply Nc E We Ldin G R E Sis Ta
    G LDIN Fine Spot Welder E WE NC IPB-5000B-MU TA DC Inverter Welding SIS Power Supply E R • Four control modes for process optimization for part manufacturing tolerances • GOOD / NO GOOD determination signals if weld was successful providing instant feedback • Displacement measurement indicates the amount of collapse the material exhibits during the weld. • Envelope feature - allows users to set dynamic profile of limits around a setting. KEY FEATURES TYPICAL APPLICATIONS • Control Modes - Optimum control modes for obtaining ideal weld quality and consistency can be chosen from; constant current control, constant voltage control, combination of constant current and constant voltage control, and constant power control. • GOOD/NO GOOD determination - The comparator feature allows to set upper and lower limits around the measured value of up to four parameters; which are current, voltage, Automotive sensor power and resistance. When those values reach out of the limits, an error signal or a caution signal alarms. • Diplacement Measurement - Measures how much an electrode moves down because of material collapse during weld. Weld to displacement - stops welding when displacement value reaches the set value. Requires displacement sensor sold separately. Electrical bussbar • Envelope - The envelope feature allows dynamic limits to be set around a monitored waveform to ensure the same resistance change occurs at the same rate for every weld. Motor armature Red: envelope Yellow: current 1/2 G TECHNICAL SPECIFICATIONS Model IPB-5000B-MU LDIN Power
    [Show full text]
  • Chapter 6 Arc Welding
    Revised Edition: 2016 ISBN 978-1-283-49257-7 © All rights reserved. Published by: Research World 48 West 48 Street, Suite 1116, New York, NY 10036, United States Email: [email protected] Table of Contents Chapter 1 - Welding Chapter 2 - Fabrication (Metal) Chapter 3 - Electron Beam Welding and Friction Welding Chapter 4 - Oxy-Fuel Welding and Cutting Chapter 5 - Electric Resistance Welding Chapter 6 - Arc Welding Chapter 7 - Plastic Welding Chapter 8 - Nondestructive Testing Chapter 9 - Ultrasonic Welding Chapter 10 - Welding Defect Chapter 11 - Hyperbaric Welding and Orbital Welding Chapter 12 - Friction Stud Welding Chapter 13 WT- Welding Joints ________________________WORLD TECHNOLOGIES________________________ Chapter 1 Welding WT Gas metal arc welding ________________________WORLD TECHNOLOGIES________________________ Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with soldering and brazing, which involve melting a lower-melting-point material between the workpieces to form a bond between them, without melting the workpieces. Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding can be done in many different environments, including open air, under water and in outer space. Regardless of location, welding remains dangerous, and precautions are taken to avoid burns, electric shock, eye damage, poisonous fumes, and overexposure to ultraviolet light.
    [Show full text]
  • Sizing the Primary Power System for Resistance Welders
    SIZING THE PRIMARY POWER SYSTEM FOR RESISTANCE WELDERS By Jack Farrow, May, 2004 WELDING TECHNOLOGY CORPORATION ABSTRACT Information on how to select the correct size of substation transformer and 480V bus to power one to one thousand resistance welding machines is presented. Powerline voltage drop, light flicker, power factor correction and harmonic currents are discussed. Strategies to allow more welders to operate on a given power system are explained. Techniques to improve the efficiency of the power system and reliability of the welding process are identified. Consideration is given to selecting the correct sizes and types of fuses. Useful reference material will be available to attendees. INTRODUCTION Because resistance welders draw large currents on an intermittent basis, they present special problems to the primary power system in a manufacturing plant. This paper answers the following questions related to these problems. 1. What size does the three-phase power system need to be to support the number of welders I have? 2. How is a welder power bus different from other power buses? 3. What can be done to improve power system efficiency and capacity utilization? 4. What is the proper size and type of fuse to use? For the purposes of discussion in this paper, spotwelding of steel sheet of thickness between 0.5 and 3 mm. is assumed. The power system supplying the welders is 480VAC, 60 HZ, three-phase. In general, the discussion is centered around standards and practices most commonly used in the North American automobile industry. I. What size does the three-phase power system need to be to support the number of welders I have? A typical resistance spotwelder draws between 100,000 and 200,000 watts when welding! To avoid problems of cold welds due to insufficient power, the 480 VAC power system must be capable of supplying this power with less than 10% voltage drop.
    [Show full text]
  • Aluminum Systems Guide
    Aluminum Systems Guide 1 The Miller ® Difference Aluminum isn’t easy to weld: It has a lower relative melting point than other metals yet requires heat to ensure proper puddle formation. Cleanliness is critical. It is more sensitive to heat input and distortion. Aluminum wire is also softer and more difficult to feed through a wire feeder and gun than other metals. High-quality welds are attainable, despite these challenges, through specialized welding systems and filler metals. Whether your shop uses aluminum exclusively or on a project- by-project basis, Miller has the MIG and TIG solutions for every application. Our complete line of easy-to-use welding equipment offers unsurpassed performance, superior puddle control and appearance, and consistent arc quality — resulting in code quality welds every time you strike an arc. Miller® aluminum MIG systems rely on advanced technology that actually simplifies welding while providing the smoothest, most consistent aluminum wire feeding on the market. Miller aluminum TIG systems provide superior arc performance and control that provide optimum quality, performance and aesthetics. Miller equipment makes aluminum welding easy, efficient and profitable — helping you improve weld quality, boost operator confidence, and keep ahead of the competition. Choose the right aluminum solution from Miller’s cost-effective, versatile, and reliable equipment for your demanding applications. 2 Your Total Welding Solutions Provider Miller is committed to providing a total aluminum Introduction to aluminum welding welding solution for your business. You can count Aluminum is specified for many reasons: it’s on our easy-to-use equipment to improve quality one-third the weight of steel, features a high and increase your productivity, profitability and strength-to-weight ratio, is corrosion-resistant and peace of mind.
    [Show full text]
  • An Experimental Investigation of Mechanical Properties of Al 6106 T6 Alloy Joined by Friction Stir Welding and TIG Welding
    International Journal of Innovations in Engineering and Technology (IJIET) An experimental investigation of mechanical properties of Al 6106 t6 alloy joined by Friction Stir Welding and TIG welding Sushil Kumar Kamat M.Tech Scholar, Om Institute of Technology & Management, Hisar Ajay Kumar Assistant Professor, Om Institute of Technology & Management, Hisar Abstract : FSW is a solid state new joining process that is presently attracting considerable interest. In this process the two pieces of metal are mechanically intermixes at the place of join, then often them so that the metal can be fused using mechanical pressure. Some aluminum alloys can be welded with electrical resistance techniques, TIG, MIG provided that an extensive surface preparation and the oxide formation is controlled. On the contrary, FSW can be used with success to weld most of Al alloys considering that superficial oxide generation is not deterrent for the process and no particular cleaning operations are needed before welding. friction stir welding was mainly developed for aluminum alloys. Al 6101 T6 aluminum alloy has been selected to perform FSW. Al 6101 alloy has been welded with FSW and TIG welding techniques. It has been found that tensile strength and hardness of FSW is more than that of TIG welding. The mechanical properties of both welding specimen has been compared and with base metal strength. Microstructure has also been examined. Keywords : FSW, TIG, Aluminum alloy I. INTRODUCTION Welding is a fabrication process used to join materials, usually metals or thermoplastics, together. During welding, the pieces to be joined ( the workpieces ) are melted at the joining interface and usually a filler material is added to form a pool of molten material ( the weld pool ) that solidifies to become a strong joint.
    [Show full text]
  • Welding Engineering
    WELDING ENGINEERING WELDING ENGINEERING AN INTRODUCTION David H. Phillips This edition first published 2016 © 2016 John Wiley & Sons, Ltd Registered Office John Wiley & Sons, Ltd, The Atrium, Southern Gate, Chichester, West Sussex, PO19 8SQ, United Kingdom For details of our global editorial offices, for customer services and for information about how to apply for permission to reuse the copyright material in this book please see our website at www.wiley.com. The right of the author to be identified as the author of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, except as permitted by the UK Copyright, Designs and Patents Act 1988, without the prior permission of the publisher. Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic books. Designations used by companies to distinguish their products are often claimed as trademarks. All brand names and product names used in this book are trade names, service marks, trademarks or registered trademarks of their respective owners. The publisher is not associated with any product or vendor mentioned in this book. Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose.
    [Show full text]
  • ATIW-1600: Welding Fundamentals for Ironworkers 1
    ATIW-1600: Welding Fundamentals for Ironworkers 1 ATIW-1600: WELDING FUNDAMENTALS FOR IRONWORKERS Cuyahoga Community College Viewing: ATIW-1600 : Welding Fundamentals for Ironworkers Board of Trustees: March 2020 Academic Term: Fall 2020 Subject Code ATIW - Appld Indus Tech - Ironworking Course Number: 1600 Title: Welding Fundamentals for Ironworkers Catalog Description: Fundamentals of welding with special emphasis on the ironworking trade. Includes welding processes; cutting and gouging processes; operational and site safety; welding equipment and tools; and safety equipment and protective clothing. Credit Hour(s): 3 Lecture Hour(s): 3 Requisites Prerequisite and Corequisite ATIW-1300 Structural Steel Concepts, and ATIW-1310 Safety for Ironworkers; or departmental approval. Outcomes Course Outcome(s): Explain welding and cutting processes. Objective(s): 1. Analyze Shielded Metal Arc Welding (SMAW). 2. Analyze Flux Core Arc Welding (FCAW). 3. Analyze Oxyfuel Burning. 4. Analyze Oxyfuel Welding. Course Outcome(s): Demonstrate welding and cutting processes. Objective(s): 1. Apply proper welding technique in the four main positions: Flat, Horizontal, Vertical, and Overhead. 2. Select proper weld process for task. 3. Ensure that all welds have proper bead formation, initiation, and termination. 4. Troubleshoot all weld processes. Course Outcome(s): Demonstrate safe operation of common welding equipment and tools on a typical job site. 2 ATIW-1600: Welding Fundamentals for Ironworkers Objective(s): 1. Explain welding power supply set up. 2. Utilize electrode holders in the welding process. 3. Utilize proper work clamps and cables. 4. Select proper electrodes. 5. Apply proper maintenance to equipment and tools on the job site. Course Outcome(s): Demonstrate the use of safety equipment and protective clothing.
    [Show full text]