Resistance Welding Courses

Update Technology Resistance Welding Course Description
586 634 6784

Factors preventing the industry from achieving uniform weld quality are:

Hidden problems: "Why didn’t we see that?"
Practices established before the introduction of today’s materials.
Over-simplified understanding of the process.

This course focuses on these issues in automotive production applications.

Good practices are established by teaching:

The basics of the resistance weld process.
The instruments used to monitor the important variables.
The weld controller’s function, features, and limitations.
A step-by-step approach to weld set-up, with methods for measuring and qualifying each step.
Weld qualification criteria and procedures.
The importance of proper documentation, and its relationship to troubleshooting.
Common and rare problems, identifying their root cause with a troubleshooting guide.
Recognizing problematic design and installation details.
Further variables and considerations introduced by robotic welding.

A student-performed weld lobe study is reviewed, along with an explanation of what must be done to adjust the findings so that they apply to the "real world of the production line".
A "short-cut" method of qualifying an existing setup is explained.
Examples of the most popular instrumentation are provided, and basic operation of the instruments are covered, to leave the student with a good comfort level with the company equipment.

Goals and Objectives

1. To make the student aware of the signs of a bad weld set-up.
2. To raise the comfort level with the equipment and the programming of the weld control.
3. To motivate students to achieve the best possible setup, by simplifying the task.
4. To teach the student how to qualify the weld setup and the results.

Prerequisites

The student must use resistance welding, and be assigned to achieving weld quality. Those that supervise or support this activity would also qualify.

General electrical knowledge is helpful, though not necessary. A general understanding of industrial machinery, including pneumatics, mechanical components and hydraulics is needed.

Safety procedures are important and the students must have good safety habits, as they pursue the knowledge gained from this course.

COURSE OUTLINE

1. Resistance welding fundamentals

1.1. Common types of automotive resistance welds

     1.1.1. Spot
     1.1.2. Seam
     1.1.3. Projection

1.2. Formation of a weld

1.3. "PTH"-Three important variables

1.3.1. Pressure

1.3.2. Time

1.3.3. Heat

1.4. Materials and their differences.

     1.4.1. Bare steel

     1.4.2. Zinc coated steel

     1.4.3. HSLA

     1.4.4. Aluminum

1.5. Suggested weld set-up information

2. Welding equipment

2.1. Weld gun parts

     2.1.1. Tip types

     2.1.2. Water tubes

     2.1.3. Shanks

2.2. Transformers

2.2.1. Capacities

2.2.2. Applications

2.3. Cables

2.3.1. Jumpers

2.3.2. Kickless cables

2.4. Welder controls

2.4.1. Line Voltage Compensation

3. Set-up procedure

3.1. Air, Water & Electricity

3.1.1. Safety, lock out procedures

3.2. Set welding force.

3.3. Set schedule

     3.3.1. Squeeze

     3.3.2. Slope or preheat

     3.3.3. Weld heat

     3.3.4. Hold

     3.3.5. Final documentation

3.4. Weld verification

     3.4.1. QC specifications

     3.4.2. Visual

     3.4.3. Peel test

     3.4.4. Tensile test

3.5. Troubleshooting

3.5.1. Basic method

3.5.2. Cold weld

3.5.3. Small nugget

3.5.4. Expulsion

3.5.5. Tip alignment

3.5.6. Shunt currents

3.6. Weld lobe study

     3.6.1. Purpose

     3.6.2. Procedure

     3.6.3. Calibration to application

4. Weld Troubleshooting

4.1. Appearance problems

     4.1.1. Discoloration

     4.1.2. Expulsion

     4.1.3. Indentation

     4.1.4. Dimpling

     4.1.5. Not round

4.2. Mechanical problems

     4.2.1. Open between sheets

     4.2.2. Distorted

     4.2.3. Expulsion

     4.2.4. Small nugget

     4.2.5. Large nugget

4.3. Strength problems

     4.3.1. Tensile strength is low

     4.3.2. Pry test breaks nugget

     4.3.3. Peel test breaks nugget

4.4. Process problems

     4.4.1. Cycle time is long

     4.4.2. Expulsion is severe

     4.4.3. Tip life is short

     4.4.4. Welds are inconsistent

     4.4.5. Cannot get enough heat

4.5. Special notes for Seam welds

4.6. Special notes for Projection welds

5. Robotic resistance welding

5.1. Robotic welding is different

     5.1.1. Duty cycle is much higher

     5.1.2. Weld schedules are more numerous

     5.1.3. Stepper schedules, more steppers are called for

     5.1.4. Tip alignment to the metal is important

     5.1.5. Tip sticking

     5.1.6. Backup programs

5.2. Setup considerations for the robotic welder

     5.2.1. Type of transformer

     5.2.2. Type of gun

6.DC Welding

     6.1. AC welding

     6.2. DC welding

7. Ultrasonic inspection of spotwelds

     7.2. Sound travel is different

     7.3. What the computer "sees"

     7.4. Good weld

     7.5. Small weld

     7.6. Stick weld

     7.7. No weld

     7.8. Other measurements

Provided by Update Technology, and ICR:

1. A manual for each student to keep is provided.

2. Highlighters and mechanical pencils are provided for each student.

3. When held at The ICR Learning Institute, a complimentary lunch is provided each day.

4. Weld setup charts are provided, although, whenever possible, the customer’s weld set-up charts are obtained and used as the guideline.

5. Instrumentation and tools are demomstrated, including:
Weld current meter,
Non-contact thermometer,
Micro-ohmmeter with Kelvin probes,
Force gage,
Flow meter,
Micrometer,
Calipers, &
Pry-check tools.

Progress Evaluation

A test is given at the start of the course, then repeated at the end of the course. This serves to accomplish three things:

1. Starts the learning process by introducing the student to details he may not be aware of.

2. Shows the improvement gained by the course.

3. Calls the instructor’s attention to student’s areas that need special attention.

There is no "failing grade", but the scores, and improvements (usually dramatic...) are announced, and any further questions are discussed at the end of the class.
The students are invited to call the instructor with questions in the future, and to submit questions as others have done and are posted (minus the name) on the internet at www.updatetechnology.com

Cost of the Course

This course is $800/student. A minimum class of five is required. The course can be held in your conference room with a/v equipment. Instructor's expenses are meals, transportation and lodging (at cost).
Additional manuals are $35 each.
For customized classes, charges may have to be added for class preparation, depending on the degree of the changes requested.
Update Technology can provide troubleshooting service; the rate is $98 per hour. References available on request.