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Copper

Copper. Resistance Welding . Learning Activities View Slides; Read Notes, Listen to lecture Do on-line workbook. Lesson Objectives When you finish this lesson you will understand:. Keywords. Copper & Iron Sulfates. Copper Ingot. Electrolytic Refined.

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Copper

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  1. Copper

  2. Resistance Welding • Learning Activities • View Slides; • Read Notes, • Listen to lecture • Do on-line workbook • Lesson Objectives • When you finish this lesson you will understand: Keywords

  3. Copper & Iron Sulfates Copper Ingot Electrolytic Refined Rosenqvist, Extractive Metallurgy McGraw-Hill, 1974

  4. Induction Furnace Melting

  5. AWS Welding Handbook

  6. AWS Welding Handbook The lower thermal & electrical conductivity materials are weldable Not Recommended Good Fair Excellent

  7. Welds can be made with sheets having 30% or less IACS No Welds with IACS over 60%

  8. Spot Welding Weld Force Weld forces are usually set to 50-70% of that used for the same thickness uncoated plain carbon steel

  9. Spot Welding Weld Current: Higher than for plain carbon steel Weld Time: Shorter than for plain carbon steel

  10. Spot Weld Experience with 65% Cu – 35% Zn Brass Increased Resistance Class 1 Class 2 Class 11 Excessive penetration Electrode Sticking Min Penetration Poor Electrode Life Increased Nugget Dia. Resistance Welder manufacturers Association Bulletin # 25

  11. Spot Welding Tungsten or molybdenum tipped electrode are preferred to minimize tip sticking Higher Resistance = Heat Soaking Lower Thermal Conductivity = Less Heat Loss

  12. More Spot Weld Experience with 65% Cu – 35% Zn Brass Cracks Under Load When Nugget Too Close to Edge Resistance Welder manufacturers Association Bulletin # 25

  13. Welding of Unequal Thickness Brass

  14. Seam Welding • Problems: • Shunting of Weld Current • High thermal conductivity • Low Electrical Contact Resistance • Result: • Limited Alloys Seam Weldable • Need Electrical Conductivity less than 30% IACS

  15. Flash Welding

  16. Flash Welding Rapid Upset Premature Interruption of Flashing Results in Low Temp & CL Defects Excessive Flashing will Overheat & Improper Upset Low Pressure at Start to get Platen Motion Immediately • Copper Characteristics: • Low melting temp • Narrow Plastic Range • Result • Rapid Upset at low force • Immediate & Full Flashing Required Savage, Flash Welding, Welding Journal March 1962

  17. Flash Welding Leaded Copper Alloys are limited to approximately 1% Lead

  18. High Frequency Welding Induction Coil HF HF HF Tube Butt Seam Tube Butt Seam Tube Mash Seam Nearly all Copper Alloys can by HF Welded - Tubing is a Popular Application

  19. Electro-Brazing

  20. Welds can be made with sheets having 30% or less IACS No Welds with IACS over 60%

  21. Electro-brazing W. Stanley, Resistance Welding McGraw-Hill, 1950

  22. Homework

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