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Nugget Development of Uncoated Steel

Nugget Development of Uncoated Steel. (a) 2 Cycles. (e) 6 Cycles. (b) 3 Cycles. (f) 7 Cycles. (c) 4 Cycles. (g) 9 Cycles. (h) 12 Cycles. (d) 5 Cycles. [Reference: EWI Research Paper: MR8814, p.19, Gould & Peterson]. Nugget Development of Electro-Galvanized Steel. (a) 5 Cycles.

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Nugget Development of Uncoated Steel

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  1. Nugget Development of Uncoated Steel (a) 2 Cycles (e) 6 Cycles (b) 3 Cycles (f) 7 Cycles (c) 4 Cycles (g) 9 Cycles (h) 12 Cycles (d) 5 Cycles [Reference: EWI Research Paper: MR8814, p.19, Gould & Peterson]

  2. Nugget Development of Electro-Galvanized Steel (a) 5 Cycles (d) 9 Cycles (b) 6 Cycles (e) 12 Cycles (c) 7 Cycles [Reference: EWI Research Paper: MR8814, p.23, Gould & Peterson]

  3. Nugget Development of Galvannealed Steel (a) 3 Cycles (e) 7 Cycles (b) 4 Cycles (f) 9 Cycles (c) 5 Cycles (g) 12 Cycles [Reference: EWI Research Paper: MR8814, p.25, Gould & Peterson] (d) 6 Cycles

  4. Nugget Development of Fe-Zn Electro-Coated Steel (d) 7 Cycles (a) 4 Cycles (b) 5 Cycles (e) 9 Cycles (f) 12 Cycles (c) 6 Cycles [Reference: EWI Research Paper: MR8814, p.27, Gould & Peterson]

  5. Electrode Alloying during Resistance Welding on Electro-Galvanized Steel HV15 Cu Zn Fe 8 90 2 28 57 15 55 45 490 130 100 10 mm

  6. Variations in Button Size during Electrode Life Testing Uncoated Steel Test Stopped at 8145 Welds Button Size (inch) Number of Welds (Thousands)

  7. Variations in Electrode Tip Size during Electrode Life Testing Uncoated Steel Test Stopped at 8145 Welds Contact Area (in.2) Number of Welds (Thousands)

  8. Variations in Button Size during Electrode Life Testing Hot-Dipped Galvanized Steel Button Size (inch) Number of Welds (Thousands)

  9. Variations in Electrode Tip Size during Electrode Life Testing Hot-Dipped Galvanized Steel Contact Area (in.2) Number of Welds (Thousands)

  10. Variations in Button Size during Electrode Life Testing Galvannealed Steel Button Size (inch) Number of Welds (Thousands)

  11. Variations in Electrode Tip Size during Electrode Life Testing Galvannealed Steel Contact Area (in.2) Number of Welds (Thousands)

  12. Weldability Lobe for Uncoated Steel Averaged from Five Individual Lobes Minimum Nominal Expulsion Welding Time (Cycles) Welding Current (kA) [Reference: EWI Research Paper: MR8802, p.17, Gould & Peterson]

  13. Weldability Lobe for Hot-Dipped Galvanized Steel Averaged from Five Individual Lobes Minimum Nominal Expulsion Welding Time (Cycles) Welding Current ( kA) [Reference: EWI Research Paper: MR8802, p.19, Gould & Peterson]

  14. Weldability Lobe for Electro-Galvanized Steel Averaged from Five Individual Lobes Minimum Nominal Expulsion Welding Time (Cycles) Welding Current (kA) [Reference: EWI Research Paper: MR8802, p.22, Gould & Peterson]

  15. Variations in Electrode Life Tests on HDG Steel Nugget Size (inch) Number of Welds (Thousands) Set 1 Set 2 Set 3

  16. Dynamic Resistance Curves (a) Uncoated Steel (b) Hot-Dipped Galvanized Steel Faying Surface Resistance Beta Peak Resistance (micro-ohme) Resistance (micro-ohme) Nugget Initiation Faying Surface Resistance Nugget Initiation Weld Time (Cycles) Weld Time (Cycles) [Reference: EWI Research Paper: MR8814, p.49, Gould & Peterson]

  17. Dynamic Displacement Curves Expulsion was evident at 6 welding cycles. Expulsion was noted at 12 welding cycles. Displacement ( x 103 inches) Displacement ( x 103 inches) (a) Weld Time (Cycles) (b) Weld Time (Cycles) [Reference: EWI Research Paper: MR8814, p.50, Gould & Peterson]

  18. Oscillating Weldability Lobe - Uncoated Steel Nominal Expulsion Tip Size Bottom Size Current (kA) Tip Size (inches) Number of Welds Number of Welds

  19. Oscillating Weldability Lobe - HDG Steel Nominal Expulsion Top Tip Bottom Tip Current (kA) Tip Size (inches) Number of Welds Number of Welds

  20. Oscillating Weldability Lobe - Galvannealed Steel Nominal Expulsion Top Tip Bottom Tip Current (kA) Tip Size (inches) Number of Welds Number of Welds

  21. Effect of Al Content in Zn Bath on Electrode Life Increased Electrode Alloying Incomplete Al2O3 Layer Electrode Life (Number of Welds) 0.5 1.0 % Al in Zn Bath

  22. Scribe Creep on Full Painted Panels Max. Total Scribe Creep (mm) [Reference: SAE Technical Paper Series: 890705, p.8, Mats Strom]

  23. Oscillating Weldability Lobe Test Results on HDG Using Cu-Al2O3 DSC Electrodes Expulsion Top Tip Nominal Bottom Tip Current (kA) Tip Size (inches) Number of Welds Number of Welds (a) Current Level Variations (b) Tip Size Variations

  24. Oscillating Weldability Lobe Test Results on HDG Using Cu-Cr Electrodes Top Tip Bottom Tip Nominal Expulsion Current (kA) Tip Size (inches) Number of Welds Number of Welds (a) Current Level Variations (b) Tip Size Variations

  25. Electrodes Used on Uncoated Steel (a) (b) (c) (d) (e) [Reference: EWI Research Paper: MR8802, p.36, Gould & Peterson]

  26. Electrodes Used on Electro-Galvanized Steel (a) (b) (c) (d) (e) [Reference: EWI Research Paper: MR8802, p.41, Gould & Peterson]

  27. Electrodes Used on Galvannealed Steel (a) (b) (c) (d) (e) [Reference: EWI Research Paper: MR8802, p.44, Gould & Peterson]

  28. Electrodes Used on Hot-Dipped Galvanized Steel (a) (b) (c) (d) (e) [Reference: EWI Research Paper: MR8802, p.39, Gould & Peterson]

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