C1 1 PDF

AWS Cl .1M E 1.
I :2000
An American National Standard
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Copyright American Welding Society

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Key Words-
Resistance weld, spot weld, seam weld,

flash weld, electrode force, weld
current, weld strength, projection
weld, lap joint, upset weld
AWS Cl .1M/C1.1:2000
An American National Standard
Approved by
American National Standards Institute
January 31,2000
Recommended Practices
for Resistance Welding

Supersedes AWS Cl.1-66
Prepared by
AWS Committee on Resistance Welding
Under the Direction of
AWS Technical Activities Committee
Approved by
AWS Board of Directors
Abstract
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This Recommended Practice is a collection of data and procedures that are intended to assist the user in setting up
resistance welding equipment to produce resistance welded production parts. While the recommendations included are
not expected to be final procedures for every production part or every welding machine, they serve as starting points
from which a user can establish acceptable welding machinesettings for specific production welding applications.
In some cases, recommended machine data is not available. In these instances, some description of the process is
given to assist the readerin determining if the process might be suitable for application.
American Welding Society

550 N.W. LeJeune Road, Miami, Florida 33126

Statement on Useof AWS American National Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American
Welding Society are voluntary consensus standards that have been developed
in accordance with the rules
of the American
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Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by
agreement between the contracting parties.
International Standard Book Number: 0-87171-601-0
American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126
O 2000 by American Welding Society. Allrights reserved
Printed in the United States of America
AWS American National Standards are developed through a consensus standards development processthat brings
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and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or
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standard. AWS also makes no guarantyor warranty as to the accuracy or completeness of any information published herein.
In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on
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on his or her own independent judgmentor, as appropriate, seek the advice
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Official interpretationsof any of the technical requirements
of this standardmay be obtained by sending a request, in writing, to the Managing Director Technical Services, American Welding Society,
550 N.W. LeJeune Road, Miami, FL 33126
(see Annex A). With regard to technical inquiries made concerningAWS standards, oral opinions on AWS standards may
be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them.
These
individuals do not speak on behalf of AWS, nordo these oral opinions constitute official
or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not
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This standard is subject to revision at any time by the AWS C1 Committee on Resistance Welding. It must be reviewed
every 5 years and if not revised, it must be either reapproved or withdrawn. Comments (recommendations,additions, or
deletions) and any pertinent data that may be of use in improving this standard are required and should beaddressed to
AWS Headquarters. Such comments will receive careful consideration
by the AWS Cl Committee onResistance Welding
and the author of the comments will be informed of the Committees responseto the comments. Guests are invited to
attend all meetingsof the AWS C1 Committee on Resistance Welding to
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appeal of an adverse decision concerningall such comments are provided in the Rules of Operation of the Technical
Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeune
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online: http://www.copyright.com.
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Personnel
F! G. Harris, Chair
W. H. Brafford, 1st Vice Chair
B. J. Bastian, 2nd Vice Chair
T. R. Potter; Secretary
J . C. Bohr
R. K. Cohen
S. A. DAnge10
**D.E. Destefan
P Dent
*R. J. Gasser
J. M. Cerken
*F! Howe
R. N! Jud
M. Kimchi
J. W Lee
*D. L. Olson
J. F! Osborne
*M. Prager
W E Qualls
W 7: Shieh
Centerline Welding, Limited

CMW, Incorporated
Benmar Associates
American WeldingSociety
General Motors Corporation
WeldComputer Corporation
Mercury Aircraft, Incorporated
High Current Technologies, Incorporated
Grumman Aircraft Systems
Consultant
Consultant
Bethlehem Steel Corporation
DaimlerChrysler Corporation
Edison Welding Institute
AlliedSigna1 Aerospace
Colorado School of Mines
Ford Motor Company
Welding Research Council
Valiant International
Lockheed Martin Corporation
*Advisor
**Correspondence
...
III

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AWS C l Committee on Resistance Welding
Foreword
(This Foreword is not a part of AWS Cl.lM/Cl.1:2000, Recommended Practices for Resistance Welding,but is included for information purposes only.)
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by the AWS Committee on Resistance

The data contained in these Recommended Practices have been compiled
Welding, by reviewing the data in the previous documents, by canvassing users of the resistance welding processes and
correlating the data thus obtained. The resulting welding schedulesshown in the tables were circulated for comments
and, in addition, some tests were conducted to ascertain that welds
of the specified strengths could be obtained.
The present edition of Recommended Practices representsan updated combination and extensionof data presented in
the previous edition of AWS Cl.l-66, Recommended Practices for Resistance Welding;AWS C1.2-53, Recommended
Practices for Spot Welding Aluminum and Aluminum
Alloys; and AWS C1.3-70, Recommended Practices for Resistance
Welding Coated Low Carbon Steels.Practices for new materials have been added and practices for materials which are
not currently resistance welded in commercial production have been deleted. The new materials include high-strength
low-alloy steels, both coated and uncoated.
AWS (3.2-53 included data for electromagnetic and electrostatic stored energy machines. Since these types of machines are rarely used anymore, having been replacedby more flexible direct energy machines, these
data have also been
deleted.
The AWS Committee on Resistance Welding has prepared these Recommended Practices in the hope that they will
serve as an incentive for industry to develop methods and procedures improving upon the practice presented herein,
which will permit the raising of quality and performance standards. If this is achieved, the Committee will have been
amply repaid for the time and effort it has devoted to this work.
Comments and suggestions for the improvement of this standard are welcome. They should besent to the Secretary,
Committee on Resistance Welding, American Welding Society,550 N.W. Laleune Road, Miami, FL 33126.
iv

STD-AWS C L = L M / C L * L - E N G L 2000
0784265 0 5 1 3 b 5 1 215
Table of Contents
Page No.
...
Personnel .................................................................................................................................................................... 111

Foreword ...................................................................................................................................................................... iv
List of Tables...............................................................................................................................................................
vi
...
List of Figures ............................................................................................................................................................ V l l l
1. Scope .....................................................................................................................................................................
2. Referenced Documents ......................................................................................................................................... 1

2.1
SafetyReferencess ...................................................................................................................................... 2
3. Nonstandard Terms and Definitions...................................................................................................................... 2
4 . Resistance Spot and Seam Welding ......................................................................................................................
4.1
UncoatedCarbonandLow-Alloy Steels ....................................................................................................
4.2 Coated Carbon and Low-Alloy Steels ........................................................................................................
4.3 Aluminum Alloys .....................................................................................................................................
4.4 Stainless Steels, Nickel, Nickel-Base Alloys, and Cobalt-Base Alloys ...................................................
4.5Copperand
Copper Alloys .......................................................................................................................
4.6 Titanium and Titanium Alloys..................................................................................................................
4.7 Welding Data Comments and Discussions Applicable to Various Metals ...............................................
4.8Weld
Discrepancies and Causes ...............................................................................................................
4.9Weld
Quality and Mechanical Property Tests ..........................................................................................
14
21
23
23
26
42
44
5 . Projection Welding ..............................................................................................................................................

5.1 Introduction ..............................................................................................................................................
5.2 EmbossedProjectionWelding ..................................................................................................................
5.3 SolidProjectionWelding ..........................................................................................................................
5.4Multiple
Projection Welding ....................................................................................................................
5.5 Weld Quality and Mechanical Property Tests ..........................................................................................
63
63
63
67
67
67
6. Flash Welding......................................................................................................................................................
6.1 Introduction ..............................................................................................................................................
6.2 Equipment.................................................................................................................................................
6.3 WeldingVariables .....................................................................................................................................
6.4 WeldingVariableMeasurements ..............................................................................................................
6.5 Classificationof Steels for Flash Welding ...............................................................................................
6.6 Joint Preparation and Cleaning.................................................................................................................
6.7Welding
Schedules ...................................................................................................................................
6.8 Weld Discrepancies and Causes ...............................................................................................................
6.9 Weld QualityandMechanicalPropertyTests ..........................................................................................
67
67
72
72
81
81
81
83
83
83
7. Upset Welding.....................................................................................................................................................
7.1 Introduction ..............................................................................................................................................
7.2 Equipment .................................................................................................................................................
7.3 WeldingVariables .....................................................................................................................................
7.4 Joint Preparation and Cleaning.................................................................................................................
7.5Welding
Parameters ..................................................................................................................................
7.6 Weld Quality and Mechanical Property Tests ..........................................................................................
86
86
86
86
86
86
86
8.
2
2
6
Weld Bonding ...................................................................................................................................................... 87

8.1 Introduction ..............................................................................................................................................
87
8.2 Aluminum Alloys ..................................................................................................................................... 87
V
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Page No
OtherMetals .............................................................................................................................................
WeldBonding Quality and MechanicalPropertyTests ............................................................................
89
90
9. Equipment Monitoring and Maintenance............................................................................................................
90
8.3
8.4
10. Safety and Health ................................................................................................................................................

1O .1 General .....................................................................................................................................................
10.2 Selection of Equipment ............................................................................................................................
10.3 OperatorTraining .....................................................................................................................................
10.4 Personal Protective Equipment .................................................................................................................
10.5Installation ................................................................................................................................................
10.6 Guarding ...................................................................................................................................................
10.7 Electrical ...................................................................................................................................................
10.8 Static Safety Devices ................................................................................................................................
10.9 Ventilation.................................................................................................................................................
10.10 Maintenance .............................................................................................................................................
1O .11 Fire Hazards..............................................................................................................................................
1O .12 Noise .........................................................................................................................................................
10.13 Lighting ....................................................................................................................................................
10.14 Signs .........................................................................................................................................................
10.15 Hazardous Materials.................................................................................................................................
Annex A-Cuidelines forPreparation of Technical Inquiriesfor AWS Technical Committees................................
94
94
94
94
94
94
94
95
96
96
96
97
97
97
97
97
103
AWS List of Documents on Resistance welding........................................................................................................ 105
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vi
List of Tables
.
1
2
3
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5
6
7
8
9
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Page No
Spot Welding Parameters for Low-Carbon Steel ........................................................................................... 4
Pulsation Spot Welding Parameters for Low-Carbon Steel ...........................................................................
5
Seam Welding Parameters for Low-Carbon Steel..........................................................................................
6
Spot Welding Parameters for HSLA Steel (ASTM A 715, Grades 50 and 60)
Minimum Yield Strengths 345 to 415 MPa (50 to 60 ksi) .............................................................................
7
Spot Welding Parameters for HSLA Steel (ASTM A 715, Grades 70 and 80)
Minimum Yield Strengths 480 to 550 MPa (70 to 80 ksi) .............................................................................
7
Spot Welding Parameters for HSLA Steel (ASTM A 568) Minimum Yield Point 380 MPa (55 ksi) .......... 8
Spot Weld Parameters for Low-Alloy and Medium-Carbon Steels ...............................................................
9
Electrode Materials for Resistance Welding................................................................................................ 10
Spot Welding Parameters for Galvanized Low-CarbonSteel ......................................................................
11
Spot Welding Parameters for Galvannealed Low-Carbon Steel ..................................................................
12
Spot Welding Parameters for Galvanized HSLA Steel Minimum Yield Strengths
345, 415, 480, 550. and 620 MPa (50,60, 70, 80, and 90 ksi) ....................................................................
13
Seam Welding Parametersfor Galvanized Low-Carbon Steel.....................................................................
13
Basic Aluminum Alloy Groups.................................................................................................................... 14
Resistance Weldability Chart for Commonly Used Combinations of Aluminum Alloys
(Based on Equal Thickness) ......................................................................................................................... 16
Recommended Spot Weld Spacing, Edge Distance. Overlap and Distance between Rows
of Welds for Aluminum and Its Alloys ........................................................................................................
18
Spot Welding Parameters for Aluminum Alloys on Standard Single-phase A-C Type Equipment............ 19
Spot Welding Parameters for Aluminum Alloys on Single-phase A-C Slope Control Type Machines......20
Spot Welding Parameters for Aluminum Alloys on Three-phase Rectifier Type Equipment .....................
21
Spot Welding Parameters for Aluminum Alloys on Three-phase Frequency Converter Type
Equipment (Single Impulse Welds)............................................................................................................. 22
Spot Welding Parametersfor Stainless Steels.............................................................................................. 24
Pulsation Spot Welding Parameters for Stainless Steels..............................................................................
25
Seam Welding Parameters for Stainless Steels ............................................................................................ 26
Spot Welding Parameters for Annealed Nickel-Copper Alloyon Single-phase Equipment ....................... 27
Spot Welding Parameters for Annealed Nickel-Copper Alloy onThree-phase Frequency
Converter Machines ..................................................................................................................................... 28
Seam Welding Parameters for Annealed Nickel-Copper Alloyon Single-phase Equipment ..................... 39
Seam Welding Parameters for Annealed Nickel-Copper Alloy on Three-phase Frequency
Converter Machines..................................................................................................................................... 30
Spot Welding Parameters for Annealed Nickel-Chromium Alloy600 on Single-phase Equipment ..........31
Spot Welding Parameters for Annealed Nickel-Chromium Alloy X750on Single-phase Equipment .......32
Spot Welding Parameters for Annealed Nickel-Chromium Alloy X750on Three-phase
Frequency ConverterMachines.................................................................................................................... 33
Spot Welding Parameters for Annealed Nickel-Chromium Alloy X750on Three-phase Dry
Disc Rectifier Machines............................................................................................................................... 34
Seam Welding Parameters for Annealed Nickel-Chromium Alloy X750 onSingle-phase Equipment ......35
Seam Welding Parameters for Annealed Nickel-Chromium Alloy X750 on
Three-phase Frequency Converter Machines............................................................................................... 36
Roll Spot Welding Parameters for Annealed Nickel-Chromium Alloy X750 on
Three-phase Dry Disc Rectifier Machines................................................................................................... 37
vi

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Table
Page No.
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35
36
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48
49
50
51
52
53
54
55
56
57
58
59
Spot Welding Parameters for Annealed Nickel

on Single-phase Equipment ..............................................
Spot Welding Parameters for Nickel-Iron-Chromium AlloyX ...................................................................
Seam Welding Parameters for Nickel-Iron-Chromium Alloy X ..................................................................

Spot Welding Parametersfor Cobalt-Chromium-Nickel Alloy ...................................................................
Spot Welding Parameters for Various Copper Alloys ..................................................................................
Spot Welding Parametersfor Titanium Alloy 6%A1-4%V..........................................................................
Variation of Current Density and Unit Force Due to Lack of Electrode Tip Maintenance..........................
Spot Welding Parameters for Various Thickness Combinations and Arrangements of
Uncoated and Coated-Carbon and Low-Alloy Steels ..................................................................................
Projection and DieGeometries for Welding a Range of Heavy-Gauge Steels ............................................
Process Requirements for Projection Weldinga Range of Heavy-Gauge Steels.........................................
Punch Design Datafor Low-Carbon Steel Projections ................................................................................
Die Button Design Data for Low-Carbon Steel Projections ........................................................................
Punch and Die Design Datafor Forming Projections on Stainless Steels ...................................................
Projection Welding Parametersfor Low-Carbon Steel ................................................................................
Projection Welding Parameters for Galvanized Low-Carbon
Steel .............................................................
Projection Welding Parameters forStainless Steels.....................................................................................
Projection Designs and Process Requirements for Annular Projection WeldingSome
Representative Light-Gauge Steels ..............................................................................................................
Projection Welding Design Datafor Stainless Steels ..................................................................................
Projections for Low-Carbon Steel .....i..........................................................................................................
Process Requirements for Cross-Wire Weldinga Range of Thicknesses of Hot- and Cold-Drawn
Steel Wires ...................................................................................................................................................
Data for Flash Welding of Tubing and Flat Sheets ......................................................................................
Data for Flash Welding of Solid Round, Hex, Square, and Rectangular Bars .............................................
Weld-Bonding Surface Preparation for Aluminum Alloys by Low-Voltage Anodizing .............................
Comparison between Resistance Spot Welding and Weld-Bonding ofAluminum Alloys .........................
Typical Spot Welding Parameters for 1.6 mm (0.063 in.) Thick 7075-T6 Aluminum Treated
with a Low-Voltage Anodizing Process .......................................................................................................
Commonly Used Metric Conversions Inch-Millimeter Conversion ............................................................
...
VI11
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38
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66
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List of Figures
Figure
1
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Page No
Standard RWMA Nose or Tip Geometries of Spot Welding Electrodes .....................................................
Coring in Nickel Alloy 718 (UNS N07718) Resistance Seam Weld. 200X ................................................
Peel Test.......................................................................................................................................................
Peel Test Specimens .....................................................................................................................................
Measurement of a Weld Button Resulting from the Peel Test.....................................................................
Bend Test Specimen .....................................................................................................................................
Spot Weld Chisel Test ..................................................................................................................................
Tension-Shear Test Specimen ......................................................................................................................
Twisting Angle y at Fracture in Tension Shear Test .....................................................................................
Cross-Tension Test Specimens.....................................................................................................................
Fixture for Cross-Tension Test(for Thicknesses up to 4.8 mm [0.19 in.])..................................................
Fixture for Cross-Tension Test (for Thicknesses 4.8 mm [0.19 in.] and Over) ...........................................
U-Test Specimen ..........................................................................................................................................
U-Tension Test Jig ........................................................................................................................................
Pull Test(90-Degree Peel Test)....................................................................................................................
Test Specimen and Typical Equipment for Torsion-Shear Test...................................................................
Drop-Impact Test Specimen.........................................................................................................................
Drop-Impact Test Machine ..........................................................................................................................
Test Fixture for Shear-Impact Loading Test ................................................................................................
Test Fixture forTension-Impact Loading Test.............................................................................................
Fatigue Testing Machine..............................................................................................................................
Pillow Test for Seam Welds.........................................................................................................................
Typical Stack-up Configuration for Embossed Projection Welding ofSheet ..............................................
Typical Configuration for Solid Projection Welding...................................................................................
Diagram Defining How Set-Down is Estimated on Cross-Wire Welds .......................................................
Characteristics of Projection Collapse during Annular Projection Welding with Different Base
Projection Widths.........................................................................................................................................
Chart of Flash WeldingDefinitions .............................................................................................................
Chart of Flash Welding Definitions.............................................................................................................
Flash Welding of Tubing and Flat Sheets ....................................................................................................
Flash Welding of Solid Round, Hex, Square, and Rectangular Bars ...........................................................
Comparison of Tensile-Shear Strengths of Uncured and Cured (Single Spot) Weld-Bonded Joints
of 7075-T6 Aluminum Alloy .......................................................................................................................
Comparison of Fatigue Test Results of Weld-Bonded and Adhesive-Bonded Joints of 7075-T6
Aluminum Alloy ..........................................................................................................................................
Fatigue Test Specimenof Weld-Bonded and Adhesive-BondedJoints .......................................................
Form for Resistance Welding Data Sheetfor Spot and Projection Welding................................................
Form for Resistance Welding Data Sheet for Seam Welding ....................................................................
Form for Resistance Welding Data Sheetfor Flash or Upset Welding......................................................
ix

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STDOAWS C L * L M / C L * L - E N G L 2000 D 078Y2b5 0 5 L 3 b 5 b 8T7

AWS Cl .1 M/C1.1:2000
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Recommended Practices
for Resistance Welding
1. Scope
Documents
2. Referenced
I t is the intent of this publication to present current

concepts and practices for resistance welding (and related processes) of ferrous and nonferrous metals including
coated and dissimilar metals. Where practical, welding
schedules are included. In other instances where schedules are too varied or the state-of-the-art is not sufficiently
developed, descriptive guidelines are included to enable
the user to establish welding procedures to meet its
requirements.
It is important to recognize that these recommended
practices are not presented as the only conditions for
welding the materials and thicknesses shown. Rather
they are offered as a guide for setting up welding schedules for any particular fabrication, and may have to be
modified according to the specific part conditions and
production requirements.
In using the data shown in the tables, it is imperative
that reference be made to the appropriate text. Failure to
refer to the text may result in misinterpretation of the
data in the tables. The text has been kept as brief as possible and all extraneous comments have been omitted.
For more detailed information on the fundamentals of
the resistance welding processes and the types of equipment utilized for the different processes, consult the current AWS Welding Handbook.
This standard makes use of both the InternationalSystem of Units (SI) and U.S. Customary Units. The measurements may not be exact equivalents; therefore, each
system must be used independently of the other without
combining in any way. The standard with the designation
c1. I M:2000 USeS units. Thestandarddesignation
c1.1:2000 USeS U.S. Customary UnitS. The latter are
shown within parenthesis ( ) or in appropriate columns in
tables and figures. An inch/millimeter conversion table is
found in Table 59.
(1) AWS Cl .4M/C1.4:2000, Specification for Resistance Welding of Carbon and Low-Alloy Steels
(2) AWS A2.4, Standard Symbols for Welding, Brazing and Nondestructive Testing
(3) AWS A3.0, Standard Welding Terms and Definitions
(4) AWS D8.6, Standard for Automotive Resistance
Spot Welding Electrodes
(5) AWS D8.7, Recommended Practices for Automotive Weld Quality-Resistance Spot Welding
(6) AWSD8.9,
Recommended Practices for Test
Methods for Evaluating the Resistance Spot Welding
Behavior ofAutomotive Sheet Steels
(7)AWS Welding Handbook, Volume 2, Eighth Edition, Chapter 17, Spot, Seam, and Projection Welding,
(8) AWS
PARW,
The ProfessionalsAdvisor
on
Resistance Welding, American Welding Society
(9) Welding Aluminum: Theory andPractice, Chapter
13 Resistance Welding, The Aluminum Association,
Washington DC, 1991
(10) ASTM E 340 and E 407, Annual Book of ASTM
Standards, Vol. 3.012
(11) ASM Handbook Volume 8: Mechanical Testing?
Resistance Welding Manual, 4 t h Edition, Resistance
Welder Manufacturers Association, 19894
1 . Available from AA, 900 19th Street, NW, Washington, DC

2ooo6.
2. Available from ~~~~i~~~ Societyfor Testingand Materials,
100
Harbor
W. Conshohocken,
PA,
19428.
3. Available from ASM lntcrnational,Materials Park, OH
44073-0002.
4. Available from RWMA, 1900 Arch Street, Philadelphia, PA
19103-1498.
1

AWS Cl .I M/C1.1:2000
(12) Society of Manufacturing Engineers, Tooland

Manufacturing Engineers Handbook, Volume 4, Fourth
Edition, 1987.s
bake-hardenable steel. Low-carbon steel having the

capability of being strengthened during a subsequent
heat treatingoperation, usually a paint baking process.
2.1 Safety References

(1) ANSI 249.1, Safety in Welding, Cutting, andAllied
Processes, published by AWS
( 2 ) Effects on Welding andHealth, published by AWS
(3) Safety and Health Fact Sheets, published by AWS
(4) Occupational Safety andHealth Administration
(OSHA), Code of Federal Regulations, Title 29 Labor,
Chapter XVII,Part 1910, Occupational Safetyand Health
Standards6
( 5 ) ANSI 2 4 1 , Personal Protection-Protective
Footwear7
(6) ANSI 287.1, Practice for Occupational and Educational Eye and FaceProtection
(7) ANSI 288.2, Respiratory Protection
(8) ANSI 289.1, Protective Headwear for Industrial
Workers
(9) ASME 815.1, SafetyStandard for Mechanical
Power Transmission ApparatusX
(10) ANSI 2535.5, Accident Prevention Tags
(1 1) National Institute for Occupational Safety and
Health, NIOSH Criteria Document, Recommended Standard for Welding, Brazing, and ThermalCutting, 1 98g9
(12) General Motors Corporation, PED 960, Personnel
Safety Standardsfor Assembly Plant Equipment and Tools,
May, 1977
(1 3) NationalFireProtectionAssociation,
National
Electrical Codeio
(14) NationalFire Protection Association, Standard
5 1 B, Cutting and WeldingProcesses
dent-resistant steel. A general term for low-carbon

steels having higher resistance to plastic deformation
than standard cold-rolled, low yield strength, lowcarbon steels. It encompasses high-strength low-alloy
(HSLA), bake-hardenable and dual-phase steels.
high-strength low-alloy (HSLA) steel. A general term

for low-carbon steel having higher yield strength than
standard low yield strength low-carbon steels. It can
be furnished as either a hot or cold rolled product.
high-strength steels (HSS). A general group of steels
with greater tensile and yield strengths than low-strength
low-carbon steel.
penetrator. A nonmetallic oxide inclusion in a flash
weld.
phase shift control. A control commonly used in resistance welding machines to adjust initiating
the
point allowing onlya portion or percentageof each alternating
current half cycle to pass to the welding transformer.
mushrooming. The deformation of an electrode, initiated at the contact surface as a result of the various actions occurring during welding.
weld discrepancy.A weld condition that deviates from
the applicable standard, specification, or engineering
drawing.
weld lobe. The current, time, and force ranges which
provide acceptable welds.
Most of the following terms are applicable only to resistance welding. Flash welding variables are defined in
6.3 For additional welding terms, see AWS A3.0, Standard Welding Terms andDefinitions.
4. Resistance Spot and Seam Welding

4.1 Uncoated Carbon and Low-AlloySteels
4.1.1 Introduction
5. Available from SME, One SME Drive, PO Box 930, Dear-
born, MI 48121.
6. Available from Superintendent of Documents, U.S. Government Printing Office, Washington,DC 20402.
7. Available from American National Standards Institute, 11
West 42nd Strect, 13th Floor, Ncw York, NY 10036-8002.
8. Available from ASME International,Three Park Avenue,
NewYork, NY 10016-5990.
9. AvailablefromNIOSH, 4676 ColumbiaParkway,Cincinnati, OH 45226.
10. Available from National Fire Protection
Association, One
Batterymarch, Quincy,PA 02269.
4.1.1.1Low-CarbonSteels.
Low-carbon steels
contain less than0.20% carbon and less than0.50% manganese, with the remaining alloying elements totaling
less than 1%. The maximum hardness attainable in carbon and low-alloy steels is dependent almost exclusively
on the carbon content. In addition to this effect on maximum hardness, carbon has a relatively strong influence
in increasing the depth or ease of hardening. Manganese
also combines with sulfur and reduces the tendency toward hot-cracking. Hot-cracking results from the low
2


--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
3. Nonstandard Terms and

Definitions
governing metal thickness. The thickness of the sheet

(usually the thinnestouter sheet) on which the required
nugget size and depth of fusion in a resistance weld
are based.
STD=AWS CL*LM/CL.L-ENGL 2000 m . 0 7 8 9 2 b 5 0 5 L 3 b 5 8 b7T

AWS C1.lM/Cl.l:2000
4.1.2SurfaceConditions.
Priorto
welding, the
workpiece surface should be free of contaminants which
might adversely affect the weld quality.Surface contaminants and organic coatings can adversely affect the
chemical composition of the weld.
Uncoated steel is typically classified as either hotrolled or cold-rolled. The hot-rolled product is supplied
in two conditions, hot-rolled, or hot-rolled, pickled and
oiled. Hot-rolled steel sheet develops a tenacious mill
scale which has a very high contact resistance. Cold-rolled
and hot-rolled, pickled and oiled steel sheets do not exhibit mill scale because the mill scale is removed during
the material processing. Low-carbon and HSLA steel sheets
are typically supplied in both the hot-rolled, pickled and
oiled, and cold-rolled conditions. Materials in these conditions are weldable as long as surface contaminants are
minimized.
4.1.1.2Medium-Carbonand Alloy Steels. Medium-carbon steels contain 0.20-0.55% carbon with the
remaining alloying elements totaling less than 1 .O%.
Steels are considered to be alloy steels when the maximum of the range given for the content of alloying elements exceeds one or more of the following limits:
manganese, 1.65%; silicon, 0.60%; copper, 0.60%; or in
which a definite range or definite minimum quantity for
any of the following elements is specified or required
within the limits of the recognized fieldof constructional
alloy steels: aluminum, and chromium up to 9%; cobalt,
niobium, molybdenum, nickel, titanium, tungsten, vanadium, zirconium,or any other alloying element added to
obtain a desired alloying effect.
Highercarbonlevelsrepresenthigherhardenability,
and care is required when welding these steels. For this
reason, medium-carbon steels have an increased tendency
toward embrittlement than do low-carbonsteels. Mediumcarbon and alloy steels frequently require preheating prior
to, and tempering treatments after, welding. These steels
may be heat treated on welding equipment with the necessary controls, or heat treated as a separate operation.
4.13 Welding Parameters. The data shown in Tables

1 through 7 are offered as a guide to develop welding
schedules for uncoated carbon and low-alloy steels.
Welding parameters in these tables should be considered
as starting points for the development of actual production welding schedules. The optimum welding schedules
may vary with different applications and with different
machines.
The following sections are comments and discussions
pertaining to the welding parameter data in these tables.
Additional comments and discussions applicable to carbon and low-alloy steels as well as other metals are presented separately in 4.7.
4.13.1 Electrodes. Resistance Welder Manufacturers Association (RWMA) Group A, Class 2 electrodes (see Table8) are generally recommended for these
steels because this group of electrodes maintains relatively high strengths at elevated temperatures. They will
have reasonable life when correctly used to weld these
steels. These electrodes are copper-chromium or copperchromium-zirconium, and exhibit higher strengths and
correspondingly reduced electrical conductivities than
Class 1 copper electrodes.
4.1.13 High-CarbonSteels. High-carbon steels

contain more than 0.55% and less than 1.50% carbon.
These steels have high hardenability and are not easily
resistance welded without weld cracking. Special procedures must be used when resistance welding these steels.
3

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
4.1.1.4 High-StrengthLow-Alloy (HSL4) Steels.

High-strength, low-alloy steels obtain their strength and
other mechanical properties through the addition of alloying elements, or through thermal processing, or both.
Alloying elements may include niobium, vanadium, nitrogen, phosphorus, or rare earth additions. Thermal processes
which impart strength include controlled cooling, recovery annealing, and controlled annealing. Yield strength
levels range from 241 MPa (35 ksi) to over 690 MPa
(100 ksi). When welding HSLA steels, welding schedules may include preweld heat conditioning, or postweld
heat treatment to improve the microstructure of the weld
nugget, HAZ, or both.
strength of the steel at high temperatures. The steel cannot accommodate the stresses which develop during
cooling, and cracks form i n the weld metal or i n the heataffected zone (HAZ).
Low-carbon steels have typical bulk electrical resistivities (.e., the specific electrical resistivity of a given
volume of metal) of 10-20 yS2-cm (4-8 @-in.), and
have large plastic ranges. Both of these characteristics
make low-carbon steel quite weldable using resistance
welding processes. However, low-carbon steels with carbon levels greater than 0.13% may be susceptible to
hardening; therefore, the rapid cooling rates of resistance
spot and seam welding are of concern for steels containing these levels of carbon. In this carbon range, precautions as described for medium and high-carbon steels
may be required.
Several new designations of low-carbon steels have
been incorporated into the nomenclature of the industry.
These include bake-hardenable, dent-resistant and interstitial-free (I-F) steels. Dent-resistant materials are defined as low-carbon steels that have higher resistance to
plastic deformation than do the standard low-carbon
steels. I-F steels are low-carbon steels which have less
than 0.02% carbon with niobium (columbium) and titanium additions to improve formability. Welding of these
materials is similar to most low-carbon steels and similar
welding schedules can be used.
STD-AWS CL.LM/CL-L-ENGL 2000
078q2b5 0513b59 50b
AWS Cl.lM/C1.1:2000
Table 1
Spot Welding Parameters for Low-CarbonSteel5
Metal2
Thickness
mm (in.)
Ele~trode.~ Net
Face
Electrode
Diameter
mm (in.)
Force
kN (lb)
Welding
Cycles
Amps
8 500
9 500
10 500
0.51 (0.020) 4.76 (0.187) 1.78 (400)
0.64 (0.025)
0.76 (0.030)
0.89 (0.035)
1 .O2 (0.040)
1.14 (0.045)
1.27 (0.050)
1.40 (0.055)
1.52 (0.060)
1.78 (0.070)
2.03 (0.080)
2.29 (0.090)
2.67 (0.105)
3.05 (O. 120)
4.76 (0.187)
6.35 (0.250)
6.35 (0.250)
6.35 (0.250)
6.35 (0.250)
7.94 (0.313)
7.94 (0.313)
7.94 (0.313)
7.94 (0.313)
7.94 (0.313)
9.52 (0.375)
9.52 (0.375)
9.52 (0.375)
Contact
Minimum4
Weld
Minimum
Shear
Overlap
mm (in.)
Spacing
mm (in.)
Strength
kN (Ib)
11.2 (0.44)
11.Y (0.47)
13.0 (0.5 1)
13.5 (0.53)
14.2 (0.56)
15.0 (0.59)
15.5 (0.61)
16.0 (0.63)
16.5 (0.65)
17.3 (0.68)
18.3 (0.72)
19.8 (0.78)
21.3 (0.84)
25.9 (1.02)
9.5 (0.37)
12.7 (0.50)
15.9 (0.63)
19.0 (0.75)
21.6 (0.85)
23.9 (0.94)
25.4 (1 .OO)
27.0 (1 .06)
28.6 (1.13)
56.5 (1.25)
36.5 (1.44)
39.7 (1.56)
42.9 (1.69)
46.0 (1.81)
Minimum
Weldh Current
Time (Approx.1
2.00 (450)
2.22 (500)
2.67 (600)
3.11 (700)
3.34 (750)
3.56 (800)
4.00 (900)
4.45 (1 000)
5.34 (1 200)
6.23 (1400)
7.72 (1 600)
8.01 (1800)
9.34 (2100)
9
9
10
11
12
13
14
16
18
20
23
26
11 500
12 500
13 O00
13 500
14 O 0 0
15 O00
16 O00
17 O00
18 O00
1 9 500
21 O00
Nugget Diameter
mm (in.)
Minimum
Satisfactory
Setup
4.57 (0.180)
1.42 (320) 3.1 (0.12)
4.57 (0.180)
2.00 (450) 3.1 (0.12)
6.35 (0.250)
2.45 (550) 3.6 (0.14)
3.34 (750) 4.1 (0.16) 6.35 (0.250)
6.35
(0.250)
4.6 (0.18) 4.11
(920)
5.12 (1150) 4.8 (0.19) 6.35 (0.250)
6.01 (1350) 5.1 (0.20) 7.94 (0.313)
7.12 (1600) 5.3 (0.21) 7.94 (0.313)
7.94(1850)
(0.313)
5.8 (0.23) 8.23
7.94 (2300)
(0.313)
6.4 (0.25) 10.23
12.01 (2700) 6.6 (0.26) 7.94 (0.313)
9.52(3450)
(0.375)
6.9 (0.27) 15.35
9.52 (4150)
(0.375)
7.1 (0.28) 18.46
9.52 (5000)
(0.375)
7.6 (0.30) 22.24
General Notes:
1. Shapes that can be used are:
E = Truncated cone (45-degbevel)
A = Pointed
B =Domed
F = Radius tip
Also see Figure 1.
2. For intermediate thicknesses, force, weld time, andcurrent may be interpolated.
3. Electrode material: RWMA Class 2.
4. Minimum weld spacing is measured from centerline to centerline.
5. The data within this table was supplied by committee members and representsan average of typical parameters used in industry.
6. Based on single-phase a-c60 Hz equipment.
7. Based on 200 MPa (30 ksi) yield strength material.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
4.13.2 Net Electrode Force. High-strength (HS)

steels typically require higher electrode forces than lowstrength, low-carbon steels. The higher forces are necessary to overcome the higher faying surface contact resistance of the HS steels and to compensate for their higher
strengths. Additionally, the bulk resistance of HS steels
is greater than for low-carbon steels, and the increase in
electrode force is used to promote proper heat balance.
HS steels may require clamping adjacent to the weld area
in order to obtain proper joint fit-up. Insulation should be
used to prevent current shunting through the clamps. HS
steels, because of their higher yield strengths, may experience excessive spring-back after completion of the
weld if the adjacent clamping force is not adequate. Excessive spring-back may result in weld fracture. However, electrodes should not be used as clamping tools to
overcome poor joint fit-up.
and low-alloy steels. Some HS steels require very short

or no hold timein order to minimize embrittlement of the
weld nugget. The hold time typical of low-strength, lowcarbon steels may quench some HS steels too quickly.
This condition is called hold time sensitivity. When
welding these steels, the welds should be checked for
this characteristic. This can be done by increasing the
hold time to 30 cycles and making another weld. After
the weld is made, test the sample in a normal peel test
and examine the weld area. If the weld exhibits interfacial fracture, or results in a partial button or cracks are
found in the metal, the material ishold time sensitive.
4.13.4 Temper Time. Medium-carbon and some

HS steels may require postweld heating in order to improve the mechanical properties of the weld. This may be
obtained by applying a separate tempering current in the
weld schedule. The weld should be cooled to a temperature below the critical temperature for martensite formation before the application of the tempering current. The
4.133 Hold Time. Typical hold time to solidify

the weld nugget varies from 5-15 cycles for low-carbon
4

S T D - A W S CL.lM/CL.L-ENGL
078112b5 0513bb0 228
2000
AWS Cl .1 M/C1.1:2000
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
o,
h
.fi
-JI
5

AWS Cl .1 M/C1.1:2000
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
Table 3
Seam Welding Parameters for Low-Carbon
Steel1$
elect rod^^.^
Width and Shape
Minimum'
76 mm
Contact
Overlap
mm (in.)
(3 in.)
RADIUS
E
Thickness 01
the Thinnest
Piece Metal
mm (in.)
W mm (in.),
min.
E mm (in.)t
0.25 (0.010)
0.53 (0.021)
0.79 (0.031)
1.02 (0.040)
1.27 (0.050)
1.57 (0.062)
1.Y8 (0.078)
2.38 (0.094)
2.77 (O. 109)
3.18 (0.125)
9.5 (0.37)
9.5 (0.37)
12.7 (0.50)
12.7 (0.50)
12.7 (0.50)
12.7 (0.50)
15.Y (0.63)
15.9 (0.63)
19.0 (0.75)
19.0 (0.75)
4.6 (O. 18)

4.8 (0.1 Y)
6.4 (0.25)
max.
7.9 (0.31)
7.9 (0.31)
YS (0.37)
11.1 (0.44)
(0.50)
Net
Electrode
Force
kN (Ib)
On Time
Cycles6
Off Time
Cycles6
2
1.78 (400)
2
2.45 (550)
3
4.00 (900)
3
4.34 (980) 6.4 (0.25)
4
4.67 (1050)
4
5.34 (1200)
6
6.67 (1500)
7
7.56 (1700)
9
8.67 (1 950) 12.7 (0.50)
9.79 (2200) 12.7 11
1
2
2
3
3
4
5
6
6
7
Weld'
Spced
m/min
(in./min)
2.0 (79)
1.9 (75)
1.8 (71)
1.7 (67)
1.7 (67)
1.6 (63)
1.4 (55)
1.3 (51)
1.2 (47)
1.1 (43)
"ILI"
Welds per
meter
Current
(in.)
Amps
&&
8 O00
11 o00
13 O00
15 O 0 0
16 500
17 500
19 O00
20 o00
21 o00
22 o00
9.5 (0.37)
11.1 (0.44)
12.7 (0.50)
12.7 (0.50)
14.3 (0.56)
15.9 (0.63)
17.5 (0.69)
19.0 (0.75)
20.6 (0.81)
22.2 (0.87)
5W (15)
470 (12)
3Yo (10)
350 (Y)
310 (8)
280 (7)
240 (6)
220 (5.5)
200 (5)
180 (4.5)
General Notes:
1. Type of steel-SAE 1010.
2. Material should be free from scale, oxides, paint, grease, and oil.
3. For the electrodes with a radius face, the face width is the same as the electrode width.
4. Electrode material: R W M A Class 2.
5. For large assemblies, minimum contactingoverlap indicated should be increased by 30 percent.
h. Based on single-phase a-c 60 Hz equipment.
7. Welding speeds noted do not give a leak-tight seam.
tempering current should not remelt the weld nugget nor

reheat the weld above theaustenitizing temperature.
with the base metal may occur, which may alter corrosion protection,
Coated steel may give off fumes while being welded.
Care should betakento
ensure proper ventilation to remove these fumes from the welding area. ventilation
is
"
4.13S Weld Current' 'Ompared

with lowstrength, low-carbon steels, HS steels have higher bulk
resistivities. For this reason, HS steels may require lower
current levels than low-carbon steels of similar thickness
in order toproduce similar weldnuggetdiameters.
addressed in 10.9.
4.2.2 Qpes of Coating. The following is a list of various types of coatings used on steels along with some
comments:
(1) Zinc-Base. These coatings are normally applied
either by hot-dipping or by electrolytic deposition.
(a) Zinc (commonly referred to as galvanized or
electrogalvanized).
(b) Zinc-aluminum (Zn + 5 percent AI).
(c) Zinc-nickel.
(d) Chromium + chromium-oxide + zinc.
(e) Zinc-iron.
(2) Aluminum-Base.
(a) Type 1 aluminum (AI with 5-10 percent silicon).
(b) Type 2 aluminum (pure AI).
(c) Aluminum-zinc (45 percent Zn + 1.5 percent Si).
4.2 Coated Carbonand Low-Alloy Steels
4.2.1 Introduction. Metallic or nonmetallic coatings

are applied to sheet steels primarily to improve thecorrosion resistance of the steel during service. These coatings, however, present some weldability concerns.
Coatings alter the contact resistance at the electrode-toworkpiece interface and faying surfaces. They generally
require increased current, which may result in increased
heating of the electrode. Coatings may cause rapid erosion of electrodes by wear, or by alloying with the electrode material. Electrode sticking due to thisalloying can
result in pitting of the electrode tip and rapid electrode
face erosion. In addition, some alloying of the coating
6

AWS Cl .1M/C1.1:2000
Table 4
Spot Welding Parameters for HSLA Steel (ASTM A 715, Grades
50 and 60)
Minimum Yield Strengths 345 to 415 MPa
(50 to 60 ksi)
Minimum Nugget
Minimum
Welding
Contact
Current Weld
Time
Overlap
(Approx.)
mm (in.)
Cycles2
Amps
3lectr0del.~
Net
Elcctrodc
Face
Diameter
Force
mm (in.)
kN (lb)
Metalh
Thickness
mm (in.)
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
0.51 (0.020)
0.61 (0.024)
0.76 (0.030)
0.91 (0.036)
1.O9 (0.043)
1.35 (0.053)
1.63 (0.064)
1.96 (0.077)
2.36 (0.093)
2.87 (O. 1 13)
3.48 (0.137)
4.6 (O. 18)

4.6 (O. 18)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
7.9 (0.31)
7.9 (0.31)
7.9 (0.31)
8.9 (0.35)
8.9 (0.35)
8.9 (0.35)
8
8
2.00 (450)
2.36 (530)
2.85 (640)
3.11 (700)
3.69 (830)
4.45 ( 1000)
5.34 (1200)
6.36 (1430)
7.70 (1 730)
9.34 (2100)
l1.12(2500)
10
11
13
21
38
51
1 1.2 (0.44)
5600
6 300 11.Y (0.47)
7 000 13.0 (0.5 1)
8 100 13.5 (0.53)
14.7 (0.58)
8 "O
15.7 (0.62)
10 o00
11 100 1716.8 (0.66)
18.0 (0.71)
12 100
13 300 20.1
28 (0.79)
14 500 20.3 (0.93)
15 700 29.7 (1.17)
Minimum
Weld
Spacing'
mm (in.)
9.5 (0.37)
12.7 (0.50)
15.9 (0.63)
19.0 (0.75)
22.9 (0.90)
26.4 (I .04)
29.7(1.17)
35. I (1.38)
46.1 (13 3 )
44.2 (1.74)
49.8 (1.96)
Minimum
Shear
Strength,
kN (Ib)
Satisfactory Setup
Diameter
Diameter
mm (in.)
mm (in.)
2.1 1 (475)
2.36 (525)
3.43 (770)
4.83 (1085)
5.76 (1295)
7.16 (1610)
1 1 .O7 (2490)
14.37 (3230)
17.30 (3890)
22.86 (5140)
26.47 (5950)
4.57 (0.180)
4.57 (0.180)
6.35 (0.250)
6.35 (0.250)
6.35 (0.250)
7.92 (0.312)
7.92 (0.312)
7.92 (0.312)
8.89 (0.350)
8.89 (0.350) 6.4 (0.25)
6.4 (0.25) 8.89 (0.350)
3.1 (0.12)
3.1 (0.12)
3.1 (0.12)
4.6 (0.18)
4.6 (O. 18)
4.6 (0.18)
4.6 (0.18)
5.6 (0.22)
5.6 (0.22)
General Notes:
1. Shapes that ciln be used are:
&Truncated cone (45-deg bevel)
A-Pointed
Also see Figure 1.
2. Data are based on single-phase a-c 60 Hz equipment.
5. Hold t i m e S e e 4.1.3.3.
6. For intermediate thicknesses, force and weld time may be interpolated.
Table 5
Spot Welding Parameters for HSLA Steel
(ASTM A 2715, Grades70 and 80)
Minimum Yield Strength485 to 550 MPa (70 to 80 ksi)
Minimum Nugget
Net
Electrode'*4
Electrode
Metal6 Face
Thickness
Force
Diameter
kN (Ib)
mm (in.) mm (in.)
Welding
Weld
Current
Time
(Approx.)
Amps
Cycles2
2.00 (450)
4.6 (0.18) 2.36 (530)
4.6 (O. 18) 2.85 (640)
6.4(0.25) 3.11 (700)
6.4 (0.25) 3.69 (830)
4.45
(1000)
6.4 (0.25) 1.35
(0.053)
6.4 (0.25) 5.34 (1 200)
7.9 (0.31) 6.36 (1430)
7.9 (0.31) 7.70 (1730)
8.9 (0.35) 9.34 (2100)
8.9 (0.35) 11.12 (2500)
0.51 (0.020) 4.6 (0.18)
0.61 (0.024)
0.76 (0.030)
0.91 (0.036)
1.O9 (0.043)
1.63 (0.064)
1.Y6 (0.077)
2.36 (0.093)
2.87 (0.1 13)
3.48 (0.137)
8
8
9
10
11
13
17
21
28
38
51
5 500
6 500
7 O00
7 900
9 O00
9 900
10 700
1 1 800
12 500
13 400
14 300
Minimum
Contact
Overlap
mm (in.)
Minimum
Weld
Spacing3
mm (in.)
1 1.2 (0.44) 9.5 (0.37)

1 1.9 (0.47) 12.7 (0.50)
13.0 (0.51)
13.5 (0.53)
14.7 (0.58)
15.7 (0.62)
16.8 (0.66)
18.0 (0.7I)
20.1 (0.79)
20.3 (0.93)
29.7(1.17)
15.9 (0.63)
19.0 (0.75)
22.9 (0.90)
26.4 (1.04)
29.7(1.17)
35.1 (1.38)
46.1 ( I .58)
44.2 (1.74)
49.8 ( 1 .96)
Minimum
Shear
Strength,
kN (Ib)
2.36 (525)
2.89 (650)
4.40 (990)
6.2 I (1 395)
7.4 I (1 665)
9 .2
1 (2070)
14.63 (3290)
18.37 (4130)
22.42 (5040) 1
29.36 (6600)
33.81 (7600)
Satisfactory
Diameter
mm (in.)
3.1 (0.12)
3.1 (0.12)
3.1 (0.12)
4.6 (0.18)
4.6 (0.18)
4.6 (O. 18)
4.6 (O. 18)
5.6 (0.22)
5.6(0.22)
6.4 (0.25)
6.4 (0.25)
setup
Diameter
mm (in.)
4.57 (O. 180)

4.57 (0. 180)
4.57 (O. 180)
6.35 (0.250)
6.35 (0.250)
6.35 (0.250)
6.35 (0.250)
7.92 (0.3 12)
7.92 (0.312)
8.89 (0.350)
8.80 (0.350)
General Notes:
I . Shapes that cm be used are:
E-Truncated cone (45-deg bevel)
A-Pointed
Also see Figure 1.
2. Data is based on sinele-ohase a-c 60 Hz eauioment.
3. Minimum weld spakng'is measured from centerline to centerline.
5. Hold t i m e S e e 4.1.3.3.
6 . For intermediate thicknesses, force and weld time may be interpolated.
I
7

AWS Cl .1 M/C1.1:2000
Table 6
Spot Welding Parameters forHSIA Steel
(ASTM A 568, Minimum Yield Point 380 MPa [55 ksi])
Metal
Thickness
mm (in.)
Electrode'
Flat Face
(Truncated
Tip)
mm (in.)
0.51 (0.020) 4.6 (0.18)

0.61 (0.024) 4.6 (O. 18)
0.76 (0.030) 6.4 (0.25)
0.9 1 (0.036) 6.4 (0.25)
1.O9 (0.043) 6.4 (0.25)
1.35 (0.053) 7.9 (0.31)
1.63 (0.064) 7.9 (0.31)
1.96 (0.077) 7.9 (0.31)
2.36 (0.093) 8.9 (0.35)
2.87 (O. 1 13) 8.9 (0.35)
3.48 (0.1 37) 8.9 (0.35)
Net
Electrode
Force
kN (Ib)
2.00 (450)
2.36 (530)
2.85 (640)
3.11 (700)
3.69 (830)
4.45 (1000)
5.34 (1200)
6.36 (1 430)
7.70 (1 730)
9.34 (2100)
1.12(2500)
Minimum
Minimum3
Minimum
Weld*
Time
Cycles
Welding
Contact
Overlap
mm (in.)
Weld
Shear
Current
Amps
Spacing
mm (in.)
Strength
kN (Ib)
8
8
9
10
5 500
6 100
6 YO0
7 700
8 700
10 O00
11 500
12 100
13 O00
14 200
15 600
11.2 (0.44)
11.9 (0.47)
13.0 (0.51)
13.5 (0.530
14.7 (0.58)
15.7 (0.62)
16.8 (0.66)
17.8 (0.70)
20.3 (0.80)
23.6 (0.93)
31.2 (1.25)
9.5 (0.37)
12.7 (0.50)
15.9 (0.63)
19.0 (0.75)
22.9 (0.90)
26.2 (1.03)
30.0 (1.18)
35.8 (1.37)
40.6 (1.60)
44.4 (1.75)
50.8 (2.00)
11
13
17
21
27
37
48
Nugget Diameter
mm (in.)
Minimum
Satisfactory
2.00 (450) 3.1 (0.12)

2.22 (500) 3.1 (0.12)
3.34 (750) 3.6 (0.14)
4.89 (1 100) 4.6 (0.18)
5.78 (1300) 4.8 (0.19)
6.78 (1 520) 5.3 (0.21)
11.56 (2600) 6.1 (0.24)
14.23 (3200) 6.6 (0.26)
16.90 (3800) 7.1 (0.28)
22.24 (5OOO) 7.8 (0.31)
27.80 (6250) 8.6 (0.34)
Setup
4.57 (0.180)
4.57 (0.180)
6.35 (0.250)
6.35 (0.250)
6.35 (0.250)
7.94 (0.313)
7.94 (0.313)
7.94 (0.313)
8.89 (0.350)
8.89 (0.350)
8.89 (0.350)
General Notes:
2. Based on single-phase a-c60 Hz equipment.
(5) Zinc-based primer.For single-side coated steel,

the higher electrical resistance caused by the zinc-based
primer can lead to short electrode life if the coating is
facing the electrode. However, the bare steel at the faying
interface improves weldability.
(6) Organic composite. These coatings are applied to
steels that have beenmetallically coated, and have undergone a chromate treatment. An organic or organic-silicate coating is the third and final layer. The composite
coatings are typically applied to one side of the steel
sheet. Paint, vinyl, or other nonconducting organic coatings may prevent direct resistance welding. The composite coatings with high electrical resistance can cause
increased electrode wear when the coating is facing the
electrode.
(7) Metallic plating. Steels may be plated with chromium, nickel, tin, zinc, copper, or cadmium. Chromium
and nickel platings have welding schedules similar to an
equivalent gauge of uncoated steel; however, an adjustment in welding current may be required. When welding
plated steels, care must be taken to provideadequate ventilation and remove any fumes which may form while
welding. For example, cadmium-plated steels, or steels
having cadmium-bearing coatings form toxic cadmium
fumes during welding. Generally, welding alters the plating in the area of the weld.
4.23 SurfaceConditions. Prior to welding, the

workpiece surface should be free of contaminants which
may adversely affect weld quality.
Zinc-coated steels can oxidize to form zinc oxide, or
white rust. White rust is a wet storage stain, and can best
be prevented by storing the coated steels in dry areas.
White rust is a nonconducting layer which can prevent
the resistance welding of coated steel. Removal of the
white rust by wire brushing or chemical cleaning prior to
welding is highly recommended.
Aluminum-coated steel may require wire brushing or
chemical cleaning prior to welding. In some instances,
the tenacious aluminum oxide layer should be removed
to minimize expulsion and electrode tip pick-up of aluminum. Care must be exercised during cleaning operations to remove the aluminum oxide layer only and not
the aluminum coating.
4.2.4 Welding Parameters. The data shown in Tables
9 through 12 are offered as a guide to develop welding
schedules for coated, low-strength low-carbon and
8

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
(8) Phosphate. Phosphate coatings have high electrical resistance and phosphate-coated steels are difficult to
weld.
A pulsation or upslope of welding current may be required to break through some of the coatings discussed
above because of their high electrical resistance.
(3) had-tin alloy (Terne coating).
(4)Tin.
AWS Cl.lM/Cl.l:2000
"
w r - 1 0
g g g
"PIN
wwww
..
602.
V
"
o - W
m m w 8
wwww
"
2 3 %
PI
"
* % 8
-
hehr
X
F


--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
oooc
AWS Cl .1 M/Cl.l:2OOO
~~
~~
~~
Table 8
Electrode Materialsfor Resistance Welding
Class
RWMA Designation
Group A-Copper Base Alloys

Cadmium copper
Class 1
Zirconium copper
1.16200
1.18200
1.15000
Class 2
Chromium copper
Chromium zirconium copper
2.18200
2.18150
Class 3
Beryllium copper (Co)
Beryllium copper (Ni)

Beryllium free
3.17500
3.17510
3.18000
Class 4
Beryllium copper
4.17200
Class 5
Aluminum bronze
5.95300
Group B-Refractory Metal or Refractory Metal Composites

Class 10
tungstenCopper
(45%Cu/55% W)
10.74450
Class 11
tungstenCopper
(25%Cu/75% W)
11.74400
Class 12
tungstenCopper
(20%CUBO%W)
12.74350
Class 13
Tungsten
13.74300
Class 14
Molybdenum
14.42300
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
Group C-Specialty Materials

Class 20
20.15760
. RWMA Group A, Class 2, materials are used for

welding coated steel because of their higher strength,
which better matches the strength of steel than Class 1.
These materials have increased resistance to annealing
(softening) and thus, mushrooming is retarded.
RWMA Group C, Class 20, dispersion strengthened
copper electrode usage has increased with the introduction of new coatings and expanded use of traditional galvanized coated steels. These electrodes have strength and
conductivity properties similar to Class 2 materials. In
addition, they exhibit greater resistance to annealing
(softening) and are noted for increased resistance to
sticking to coated material.
HSLA steels. The following sections are comments and

discussions pertaining to these data. Additional comments and discussions applicable to carbon and lowalloy steels as well as other metals are presented separately in 4.7.
4.2.4.1 Electrodes (See Table 8)

4.2.4.1.1 ElectrodeMaterial.
Industryuses
several electrode materials for the resistance welding of
coated steels. The individual application, including size,
shape, materials being welded and weld schedule, has
dictated different material selections. These electrode
materials are selected for the following characteristics
and properties:
RWMA Group A, Class I , materials are relatively
weak electrode materials, but they exhibit the highest
conductivity. Theycan conduct the increased currents associated with coated steels and cool the face quicker,
which can retard alloying between the coating and the
electrode.
4.2.4.1.2 ElectrodeShape. There are several

standard and nonstandard electrode shapes available (see
Figure 1). Seam weld-ng electrode configurations are
available in wheel form. Wire-wheel seam welding,
which uses a continuously fed wire as an intermediate
electrode between the electrode wheel and the workpiece, is also an acceptable configuration.
10

Table 9
Spot Welding Parameters for Galvanized Low-Carbon Stee1117
I
Electrode3
Mcta14
Thickness
mm (in.)
Face
Diameter
mm (in.)
Shapeh
Net
Electrode
Force
kN (Ib)
0.51 (0.020) 4.76 (0.187) A, B, E 2.1 1 (470)

2.34 (530)
0.64 (0.025) 4.76 (0.187) A, B, E
2.56 (580)
0.76 (0.030) 6.35 (0.250) A, B, E
0.89 (0.035) 6.35 (0.250) A, B, E, F 2.78 (620)
E, F 3.11 (700)
A, B, (0.040)
6.35 (0.250) 1.02
1.14 (0.045) 6.35 (0.250) A, B, E, F 3.34 (750)
A, B, (0.050)
E, F 3.56 (800)
7.94 (0.313) 1.27
A, B, E, F 4.45 (1OOO)
(0.055) 7.94 (0.313) 1.40
1.52 (0.060) 7.94 (0.313) A, B, E, F 4.56 (1 030)
A, B,(0.070)
E, F 5.45 (1230)
7.94 (0.313) 1.78
A, B, E, F 6.12 (1380)
(0.080) 7.94 (0.313) 2.03
2.29 (O.Ou0) 9.52 (0.375) A, B, E, F 6.67 (1 500)
A, B, E, F 7.67 (1 720)
(0.105) 9.52 (0.375) 2.67
3.05 (0.120) 9.52 (0.375) A, B, E, F 9.34 (2100)
Weld
Weldz Current
Time (Approx.:
:ycles Amps
10
11
12
13
13
14
16
17
18
22
25
31
35
42
Nugget Diameterss
Minimum
Minimum
Minimum
Contact
Overlap
mm (in.)
Weld
Minimum
Spacing Satisfactory Setup
mm (in.) mm (in.)
mm (in.)
Shcar
Strength
kN (Ib)
11.2 (0.44)
11.9 (0.47)
11.9 (0.47)
13.5 (0.53)
13.5 (0.53)
15.0 (0.59)
15.0 (0.59)
16.0 (0.63)
16.0 (0.63)
16.8 (0.66)
18.3 (0.72)
19.8 (0.78)
21.3 (0.84)
22.4 (0.88)
10900
11500
12300
13500
14 100
14800
15600
16200
17000
18800
19600
20400
22000
24000
9.5 (0.37)
15.9 (0.63)
15.9 (0.63)
19.0 (0.75)
19.0 (0.75)
20.3 (0.94)
20.3 (0.94)
27.0 (1.06)
27.0 (1.06)
30.0 (1.18)
34.9 (1.37)
39.7 (1.56)
42.7 (1.68)
46.0 (1.81)
3.0 (0.12)
3.3 (0.13)
3.6 (0.14)
4.1 (0.16)
4.3 (0.17)
4.8 (0.19)
5.1 (0.20)
5.3 (0.21)
5.6 (0.22)
6.1 (0.24)
6.6 (0.26)
6.9 (0.27)
7.1 (0.28)
7.6 (0.30)
4.6 (0.18) 1.42 (320)

4.6 (0.18) 2.00 (450)
5.1 (0.20) 2.56 (580)
6.4 (0.25) 3.34 (750)
6.4 (0.25) 4.1 1 (920)
6.4 (0.25) 5.12 (1150)
7.9 (0.31) 6.01 (1350)
7.9 (0.31) 7.12 (1600)
7.9 (0.31) 8.23 (1850)
7.9 (0.31) 10.23 (2300)
7.9 (0.31) 12.01 (2700)
9.5 (0.37) 15.35 (3450)
9.5 (0.37) 18.46 (4150)
9.5 (0.37) 22.24 (5000)
General Notes:
1. Welding parameters are applicable to welding two stack joints of one-sided or two-sided galvanized low-carbon steel.
2. Welding parameters are based on single-phase a-c 60 Hz equipment.
3. Welding parameters are applicable when using electrode materials included in R W M A Classes 1,2, and 20.
4. Metal thicknesses represent the actual thicknessof the sheets being welded. In the case of welding two sheets of different thicknesses, use the welding
parameters for the thinner sheet.
5. Nugget diameters are listed as:
-the minimum diameter that is recommended to be considered a satisfactoryweld.
-the initial aimsetup nugget diameter that is recommended in setting up aweld station to produce nuggets that consistently surpess the satisfactory
weld nugget diameter for a given number of production welds.
6. Electrode shapes listed include: A-pointed, B-domed, E-truncated, F-radiused.
Figure I shows these shapes.
7. These recommendations are based on
available weld schedules representing recommendationsfrom resistance welding equipment suppliers andusers.
~
4.2.4.13 Electrode Life. Electrode life can be

defined as the number of welds that can be made with a
pair of electrodes and maintain weld button diameters
above a specified minimum value.
Coated steel typically shortens electrode lifemore
than uncoated steel. The coating may alloy with the copper electrode and result in electrode sticking and pitting
of the electrode face. Coatings that contain zinc, aluminum, tin, or cadmium can alloy easily with the copper
electrodes. Different coatings result in different electrode
wear characteristics.
Coated HS steels typically require higher forces than

coated low-strength, low-carbonsteels (see 4.1.3.2).
4.2.43 Weld Time. Coated steel requires longer

weld time than uncoated steel. Weld time may need to be
increased as the coating thickness increases.
4.2.4.4 Hold Time. Short hold time may be necessary for coated steels in order to reduce electrode sticking. Coated HS steels may require very low hold time
(see 4.1.3.3).
4.2.4.5 Temper Time. Temper time may be incorporated into the welding schedule when welding coated
HS steels and medium-carbon steels. These steels may
require heat treatment after being welded in order to improve the mechanical properties of the weld. After completing the weld, the welding cycle will go through a
quench time (sometimes referred to as the cool time),
during which no current flows through the workpiece,
and the weld is rapidly cooledby the electrodes. The temper time follows the quench time. Tempering is obtained
4.2.4.2 Net Electrode Force. Coated steels typically require higher electrode forces t h a n uncoated
steels. This is especially true for steels with multilayered
coatings or primers. Phosphate coatings have very high
electrical resistances and may prevent the passageof current at low electrode forces. Steels with thin phosphate
coatings can be welded satisfactorily; however, even at
higher electrode forces, slight variations i n phosphate
coating thickness can result in inconsistent weld quality.
11
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


AWS Cl .1M/C1.1:2000
Table 10
Spot Welding Parameters for Galvannealed Low-Carbon Stee1117
Nugget Diameterss
Electrode3
Mcta14
mm (in.)
FdCe
Diameter Thickness
mm (in.)
Shape6
Weld
Net
Electrode Weld2 Current
Force
kN (Ib)
1.67 (380)
0.51 (0.020) 5.08 (0.200) A, B, E
1.78 (400)
A, B, E
(0.025) 5.08 (0.200) 0.64
2.00 (450)
E
A, B, (0.030)
5.08 (0.200) 0.76
0.89 (0.035) 6.35 (0,250) A, B, E, F 2.67 (600)
1.02 (0.040)6.35 (0.250) A, B, E, F 2.89 (650)
1.24 (0.045) 6.35 (0.250) A, B, E,F 3.34 (750)
1.27 (0.050) 7.94 (0.313) A, B, E, F 3.56 (800)
1.40 (0.055) 7.94 (0.313) A, B, E, F 4.00 (900)
1.52 (0.060) 7.94 (0.313) A, B, E, F 4.45 (1 O00)
B, E,
F 5.34 (1 200)
7.94 (0.313) A,
1.78
(0.070)
2.03 (0.080) 7.94 (0.313) A, B,E, F 5.78 (1 300)
A, B, E, F 6.67 (1 500)
(0.090) 9.52 (0.375) 2.29
A, B,(0.105)
E, F 8.0 1 (1 800)
9.52 (0.375) 2.67
A, B,(0.120)
E, F 9.34 (2100)
9.52 (0.375) 3.05
Time (APProx
Cycle! Amps
6
7
8
9
10
11
12
13
14
16
18
20
23
26
Minimum
Minimum
(hltdct
Overlap
mm (in.)
Weld
Minimum
Spacing Satisfactor) Setup
mm (in.)
mm (in.) mm (in.)
8000 1 1.2 (0.44)

9000 11.9 (0.47)
10 500 1 1.9 (0.47)
11 500 13.5 (0.53)
12 500 13.5 (0.53)
13 O00 15.0 (0.59)
14 O00 15.0 (0.59)
14 500 16.0 (0.63)
15 O00 16.0 (0.63)
16 500 16.8 (0.66)
17 500 18.3 (0.72)
19 000 19.8 (0.78)
20 o00
21.3 (0.84)
21 o00 22.4 (0.88)
9.5 (0.37)
15.9 (0.63)
15.9 (0.63)
19.0 (0.75)
19.0 (0.75)
23.9 (0.94)
23.9 (0.94)
27.0 (1.06)
27.0 (1.06)
30.0 (1.18)
34.0 (1.37)
39.7 (1.56)
42.7 (158)
46.0 (131)
2.5 (O. 10)

3.1 (0.12)
3.6 (0.14)
4.1 (0.16)
4.8 (O. 19)
5.1 (0.20)
5.6 (0.22)
6.1 (0.24)
6.6 (0.26)
7.1 (0.28)
7.4 (0.29)
8.1 (0.32)
8.4 (0.33)
8.6 (0.34)
Minimum
Shear
Strength
kN (Ib)
5.1 (0.20) 1.42 (320)
5.1 (0.20) 2.00 (450)

5.1 (0.20) 2.56 (580)
6.4 (0.25) 3.34 (750)
6.4 (0.25) 4.11 (920)
6.4 (0.25) 5.12 (1150)
7.8 (0.31) 6.01 (1350)
7.8 (0.31) 7.12 (1600)
7.8 (0.31) 8.23 (1850)
7.8 (0.31) 10.23 (2300)
7.8 (0.31) 12.01 (2700)
9.5 (0.37) 15.35 (3450)
9.5 (0.37) 18.46 (4150)
9.5 (0.37) 22.24 (5000)
General Notes:
1. Welding parameters are applicable lo weldingtwo stack joints of one-sided or two-sided galvannealedsheets of low-carbon steel.
2. Welding parameters are based on single-phase a-c 60 Hz equipment.
3. Welding parameters are applicable when using electrode materials included in RWMAClasses 1,2, and 20.
4. Metal thicknesses represent the actual thicknessof the sheetsbeing welded. In the case of welding two sheets of different thicknesses, use the welding
parameters for the thinner sheet.
5. Nugget diameters are listed as:
the minimum diameter that is recommended to be considered asalishctory weld.
surpass the satisfactory
-the initial aimsetup nuggetdiameter that is recommended in setting up a weld station to produce nuggets that consistently
weld nugget diameter for a given number of productionwelds.
h. Electrode shapes listed include: A-pointed, B-domed, &truncated, F-radiused.
Figure 1 shows these shapes.
7. Thcse recornmendations are based
on available weld schedules representing recommendations rrom resistance
weldingequipment suppliers andusers.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
for the weld nugget. For this reason, increased coating

weights may require higher welding current or longer
weld time, or both.
HS steels have higher bulk electrical resistivities than
low-carbon steels. For this reason, coated HS steels may
require lower current levels than coated low-carbon
steels of similar thickness to produce similar nugget
diameters.
Most coatings increase the area of contact with the
electrode face. The increased contact area results in decreased current density as compared to uncoated steel.
The higher currents required for welding coated steels
can lower the electrode life due to increased electrode
heating. The welding current working envelope (lobe),
for coated steel is narrower than thatfor uncoated steel.
Zinc- and zinc-alloy coated steels require higher current than uncoated steels.
Cadmiumand
tin-coated
steels require welding
schedules similar to zinc-coated steels, but may require
lower currents. Aluminum- and aluminum-alloy coated
by applying an additional current, the magnitude of

which is a fractional value of the original welding current. The weld should be cooled to a temperature below
the critical temperature for martensite formation before
application of the tempering current. The tempering current must not remelt the weld nugget, and should not reheat the weldabove the austenitizing temperature. Proper
setup for any particular alloy may require considerable
adjustment of the quench and temper times, and of the
temper current level for best results.
4.2.4.6 Welding Current. Coated steels typically
require higher currents than uncoated steels. The presence of molten coatings at the faying surfaces during
welding provides a shunting path for the current. The
coating is displaced from the weld area after melting, and
surrounds the weld nuggetin the form of an annular ring.
The molten coating has a lower electrical resistance than
the base metal. Current shunting through the annular ring
of molten coating results in a decrease in current density
12

AWS Cl .1 M/C1.1:2000
I
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
Table 11
Spot Welding Parameters for GalvanizedHSLA Steel'?
Minimum Yield Strengths345,415,480,550, and 620 MPa (50,60,70,80, and 90 ksi)
Metal4
Thickness
mm (in.)
-r
Electrode'
Face
Diameter
mm (in.)
Shape6
Weld Current
Amps
480, 550,
Minimum
Contact
Overlap
mm (in.)
345 and
and
+ILI"
Net
115 MPa 620 MPd
Electrode Weld2
and
(70,80, (50
Time 60 ksi) and 90 ksi)
Force
Grades
kN (Ib) Cycle! Grades
0.51 (0.020) 4.76 (0.187) A, B, E

2.00 (450)
0.64 (0.025) 4.76 (0.187) A, B, E
2.22 (500)
A, B,
E
6.35 (0.250) 0.76
(0.030)
2.42 (540)
A, B,
E, F 2.89 (650)
6.35 (0.250) 0.89
(0.035)
1.02 (0.040) 6.35 (0.250) A, B, E, F 3.00 (670)
1.24 (0.045) 6.35 (0.250) A, B, E, F 3.43 (770)
A, B,(0.050)
E, F 3.67 (830)
7.94 (0.313) 1.27
1.40 (0.055) 7.94 (0.313) A,B,E, F 4.56 (1030)
A,B,
E, F 5.16 (1160)
7.94 (0.313) 1.52
(0.060)
A, B,(0.070)
E, F 5.60 (1260)
7.94 (0.313) 1.78
A, B,(0.080)
E,F 6.18(1390)
7.94 (0.313) 2.03
A, B,(0.090)
E, F 8.01 (180)
9.52 (0.375) 2.29
A, B,(0.105)
E, F 8.14 (1830)
9.52 (0.375) 2.67
3.05(0.120) 9.52 (0.375) A, B, E, F 9.70 (2180)
10
10
11
12
12
13
14
15
17
21
23
29
35
42
8600 7900
1 1.1 (0.44)
9400 8600
1 1.9 (0.47)
9 900
8 800
11 .Y (0.47)
11 200
10 100
13.5 (0.53)
11 500 10 200
13.5 (0.53)
11 200
12300
15.0 (0.59)
12 700
11 300
15.0 (0.59)
13400 14600
16.0 (0.63)
13 700 15 O00
16.0 (0.63)
15200
14200
16.8 (0.66)
14 700 15 18.3
700 (0.72)
15 500 1619.8
500(0.78)
21.4 (0.84)
16800
15800
I 6 700 17 22.4 (0.88)
800
Nugget Diameterss
+I
Minimum
Weld
Spacing
$to
mm (in.)
ICDo
Minimum
Satisfactory setup
mm (in.) mm (in.)
9.5 (0.37) 3.1 (0.12)

15.9 (0.63) 3.3 (0.1 3)
15.9 (0.63) 3.6 (O. 14)
19.5 (0.75) 4.1(0.16)
19.5 (0.75) 4.3 (0.17)
23.8 (0.94) 4.8 (0.19)
23.8 (0.94) 5.1 (0.20)
26.9 (1.06) 5.3 (0.21)
26.9 (1.M) 5.6 (0.22)
30.0 (1.18) 6.1 (0.24)
34.9 (1.37) 6.6 (0.26)
39.6 (1.56) 6.9 (0.27)
42.7 (1.68) 7.1 (0.26)
46.0 (1.81) 7.6 (0.30)
4.6 (O. 18)

4.6 (0.18)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
7.9 (0.31)
7.9 (0.31)
7.9 (0.31)
7.9 (0.31)
7.9 (0.31)
9.5 (0.37)
General Notes:
1. Welding parameters are applicableto welding twostack jointsof one-sided or two-sided galvanized high-strength low-alloysteels.
2. Welding parameters arebased on single-phase a-c60 Hz equipment.
3. Welding parameters are applicablewhen using electrode materials included in RWMA Classes 1.2, and 20.
4. Metal thicknesses represent the actual thickness
of the sheets being welded. I n the caseof welding two sheetsof different thicknesses,use the welding
parameters forthe thinner sheet.
5 . Nugget diameters arelisted as:
-the minimum diameter that is recommended to be considereda satisfactory weld.
consistently surpassthe satisfactory
-the initial aim setup nugget diameter that is recommended i n setting up a weld station to produce nuggets that
weld nugget diameter for a given number of production welds.
6. Electrode shapes listed include: A-pointed, E-domed, E-truncated, F-radiused. Figure
1 shows these shapes.
7. These recornmendationsare based on available weld schedules representing recommendations from resistance welding equipment suppliers and users.
Table 12
Seam Welding Parameters for Galvanized Low-Carbon Steel'
Electrode2
Metal
Thickness
mm (in.)
0.25 (0.010)
0.53 (0.021)
0.78 (0.031)
1 .O2 (0.040)
1.27 (0.050)
1.57 (0.062)
1.98 (0.078)
2.39 (0.094)
2.77 (0.109)
3.18 (0.125)
Wheel Body
Width
mm (in.)
Contact4
Face Width
mm (in.)
4.76 (0.187)
9.52 (0.375)
4.76 (O. 187)
9.52 (0.375)
12.70 (0.500) 6.35 (0.250)
6.35 (0.250)
12.70 (0.500)
7.94 (0.313)
12.70 (0.500)
7.94 (0.3 13)
12.70 (0.500)
9.52 (0.375)
15.88 (0.625)
15.88 (0.625) 11.11 (0.437)
19.05 (0.750) 12.70 (0.500)
19.05 (0.750) 12.70 (0.500)
Net
Electrode
Force
kN (Ib)
2.2 (500)
2.7 (600)
4.0 (900)
4.9 (1 100)
5.8(130)
6.7 (1500)
7.6 (1700)
8.5 (1 900)
9.3 (2100)
10.2 (2300)
Weld
On
Time
Cycles
Weld
Off
Time
Cycles
2
2
3
3
4
4
6
7
9
11
1
2
2
3
3
4
5
6
6
7
Welding
Current
Amps
Minimum3
Contact
Overlap
mm (in.)
10 O00
2.0 (80) 381 (15)
13 O00
1.9 (75) 305 (12)
15 O00
1.8 (71)
254 (10)
17 O00
1.7 (67) 239 (9)
19 O00
1.6 (63)
22Y (8)
21 O00
178 (7) 1.6 (63)
22 500
1.4 (55)
152 (6)
24 O00
140 (5.5) 1.3 (51)
25 O00
1.2 (47)
127 (5)
26 O00
114 (4.5) 1.1 (43)
9.5 (0.37)
11.1 (0.44)
14.2 (0.56)
14.2 (0.56)
14.2 (0.56)
16.0 (0.63)
17.5 (0.69)
19.0 (0.75)
20.6 (0.81)
22.2 (0.88)
Welding
Speed
m/min
(in./min)
Welds per
Meter
(in.)
General Notes:
I . Welding parameters are applicablefor seam welding low-carbon galvanized steels.
2. Welding parameters are applicableusing electrode materials included in RWMA Classes 1. 2, and 20.
3. For large assemblies, the minimum contacting overlap should be increased 30%.
4. The contact face widths in the lable are for flat Pace with bevel sides electrode setups. An alternative is a 75 mm (3 in.) radiused contact face that
would be across the entire wheel body width.
13

AWS C l .1 M/C1.1:2000
TYPE "A"
POINTED
TYPE 'B"
DOME
TYPE "C"
FLAT
TYPE "D"
OFFSET
TYPE "E"
TRUNCATED
TYPE "F
RADIUS
Figure 1-Standard RWMA Nose or Tip Geometriesof Spot Welding Electrodes
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
(2) Aluminum has a narrow plastic temperature

range. This and its high thermal expansion and contraction may require the use of special weld
force application
sequences utilizing rapid follow up, along with low inertia equipment for some applications.
(3) Aluminumreadily oxidizes on the surface, producing a high and inconsistent resistance. Removal of
this oxide requires a chemical or mechanical cleaning
process.
(4) Aluminum alloys fall into two general classifications, heat treatable and non-heat treatable. The non-heat
treatable alloys may be hardened by cold working to
some degree. Table13 shows the alloy designationgroups
and major alloying elements. An indication is also given
steels may require higher current compared to zinccoated and uncoated steels. Aluminum-zinc-coated steels
require currents slightly less than for zinc-coated steels.
Spot welding schedules for zinc-based primer and organic compositecoated steels are similar to those for metallic-coated steels, but may require lower welding
currents.
Series or parallel welding may be difficult for coated
steels. Secondary circuit variations make it difficult to
control weld quality, due to nonuniform metal conditions
and electrode deterioration at the paired weld locations.
In addition, series welding relies on the workpiece to
conduct weld current from one electrode to the other,
which can prove difficult with coated steels.
4.2.5 Seam Welding. Seam welding coated steel requires more control over welding conditions than spot
welding. Proper control is necessary at higher speeds
since the weld is not contained by the electrode force.
Excessive welding speeds and high currents can cause
cracking in resistance seam welds.
Table 13
Basic Aluminum Alloy Groups
Major
Designation'
Elements
Alloying
43. Aluminum Alloys
90.0%Min. Aluminum
43.1 Introduction. The resistance welding of aluminum and aluminum alloys is considerably different from
other metals due to the physical and chemical properties
described below:
(1) Aluminum and its alloys have substantially higher
thermal and electrical conductivities than most materials
that are resistance welded.
This necessitates the
use of
higher
welding current and shorter welding
time.
Copper
Manganese
Silicon
Magnesium
Magnesium and Silicon
Zinc
1xxx
2xxx2
3xxx
4xxx
sxxx
hxxx2
7xxx2
General Notes:
,.
Association designations.
2. Heat-treatable
alloys.
14

AWS Cl .1 M/Cl.1:2000
as to whether the alloy designation is considered heat

treatable. In general, the high-strength heat treatable alloys (2000, 6000, and 7000 series) have a greater tendency toward weld cracking and porosity than other
alloys.
( 5 ) The temper ofan aluminum alloy influences its
weldability, with the soft tempers being generally more
difficult to weld. Deformation under the electrode force
causes variations in current and force distribution that
can result in inconsistent weld strength.
(6) A heat treatable aluminum alloy of a given temper
may have a wide range of bulk electrical conductivity.
This can cause inconsistent welds with inadequate size
or
penetration. Heat treating conditions should beclosely
monitored to control this condition.
The weldability of various alloys and tempers in similar and dissimilar combinations is shown in Table 14.
43.2 Surface Condition.The high surface resistance

of aluminum and its alloys as received from the mill is
due to the presence of a film of aluminum oxide and
other contaminants from the rolling or extruding process.
This surface resistance is nonuniform and, in most cases,
prevents consistent weld strength and quality. The
preweld cleaning should yield a clean surface of uniform
electrical resistance. This surface will reduce variations
in welding heat at the joint interface, and improve weld
consistency. The parts should be weldedas soon as possible after cleaning. The acceptable holding period, or
elapsed time between cleaning and welding, may vary
from a few hours to 48 hours, or more, depending on the
cleaning process used, cleanliness of the shop, the particular alloy, and other factors.
The surface may be cleaned, either chemically or mechanically, as described below:
(1) Chemical Cleaning.The chemical solution cleaning process is desirable for large production volumes.
Several steps are involved in the cleaning. A non-etching
alkaline cleaning solution should be used first to remove
heavy oils or grease, followed by a water rinse. Use precaution when handling alkaline (caustic) solutions. They
can cause chemicalburns and violent chemical reactions
can result when mixed with acids. Before use, read and
understand the manufacturers instructions, Material
Safety Data Sheets (MSDSs), and your employers safety
practices. The next step is immersion in a solution to remove the oxide film followed by a water rinse. The final
step should be drying with forced air with or without
heat.
The chemical solutions should be maintainedatthe
proper strengths to ensure satisfactory surface preparation. The concentration may be determined by titration,
and additions of chemicals to the solutions should be
made when necessary. The cleaning effectiveness of the
solutions can be adversely affected by contamination.

Contaminated solutions should be drained and replaced.
The principaladvantages of chemical cleaning are
low unit cost, large production capacity, and uniform results. The principal disadvantages are high capital investment, exacting controls, and the cost and difficulty of
waste disposal.
(2) MechanicalCleaning, The useofmechanical
cleaning is generally restricted to small productionquantities or isolated spots on large pieces where it is not
necessary or economical to clean the entire piece. Mechanical cleaning is recommended when lap joints are
present that canentrap chemical solutions.
A precleaner, suchas avapor degreaseror alkaline solution, is usually necessary to remove foreign substances
prior to mechanical cleaning. The surface to be cleaned
may be abraded by a stainless steel wire wheel, abrasive
cloth, or abrasive-impregnated nylon wheel. Wire brush
bristles should not exceed 0.13 mm (0.005 in.) diameter,
and abrasive wheels or paper should not be coarser than
240 grit or the surface can become too coarse. Residual
particles from the abrading process must be removed
prior to welding.
The principal advantages of mechanical cleaning are
low capital investment and the ease of cleaning localized
areas. The principal disadvantages are highunit cost, because this process is generally a hand operation, and the
difficulty of assuring uniform cleaning. Automated
equipment able to clean large sheets can eliminate some
of these disadvantages.
4 3 3 Welding Parameters. The data shown in Tables

14 through 19 are offered as a guide to developing spot
welding schedules for aluminum and its alloys. With the
number of variables involved, it is impractical to specify
welding parameters for every condition or combination.
The parameters presented are for the most commonly
welded alloys and thicknesses. Althoughno seam welding
data are given, seam welding parameters can be developed. Some of these spot welding data can be usedin developing the seam welding schedules because of the
similarity of the two processes. Higher currents are generally needed in seam welding to overcome the effectof current shunting through previously formed welds. Projection
welding of aluminum and its alloys is not recommended
because of their narrow plastic temperature ranges.
The following sections are comments and discussions
pertaining to the welding schedule data in these tables.
Additional comments and discussions applicable to aluminum alloys as well as well as other metals are presented separately in 4.7.
433.1 Electrodes. RWMA Group A, Class 1,
copper electrodes are the most commonly used for resistance welding aluminum and its alloys. RWMA Class 1
15
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


AWS Cl .1 M/C1.1:2OOO
y?
m
x
O
16
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


S T D = A W S C l * l M / C L = L - E N G L 2000 m 078112b5 05L3b72 T q T m
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
AWS Cl.lM/C1.1:ZOO0


lg
v)
I Es
a
.-C
0:
c49 0
?$
e
rl
r-
n!
rl
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
d
o
C
Q
c,
U)
H3
e
'"o
1%
w
o,
w
C
E"E
8
0,
18

STDmAWS C L - L M / C L = L - E N G L 2000
07842b5 0 5 L 3 b 7 4 &L2
AWS Cl.lM/C1.1:2000
Table 16
Spot Welding Parameters for Aluminum Alloys
on Standard Single-Phase A-C Type Equipment2
Electrode Diameter and Shape'
Sheet
Thickness
mm (in.)
D
mm (in.)
0.41 (0.016)
0.51 (0.020)
0.64 (0.025)
0.81 (0.032)
1.o2 (0.040)
1.27 (0.050)
1.h0 (0.063)
1.80 (0.071)
2.03 (0.080)
2.29 (0.090)
2.54 (O. 100)
3.18 (0.125)
15.9 (0.63)
15.9 (0.63)
15.9 (0.63)
15.9 (0.63)
15.9 (0.63)
15.9 (0.63)
15.9 (0.63)
15.9 (0.63)
22.2 (0.87)
22.2 (0.87)
22.2 (0.87)
22.2 (0.87)
Radius
mm (in.)
Top Electrode
3ottom Electrode
Flat
1
2
2
Flat
Flat
Flat
Flat
Flat
Flat
4
4
6
6
6
4
4
6
6
6
Net Electrode
Force (Weld)
kN (Ib)
1.42 (320)
1.51 (340)
1.73 (390)
2.22 (500)
2.67 (600)
2.96 (660)
3.34 (750)
3.56 (800)
3.83 (860)
4.23 (950)
4.67 (1050)
5.78 (1300)
Welding
Current
Approx.
Amps
Welding?
Time
Approx.
(Cycles)
15 O00
18 O00
21 800
26 o00
30 700
33 o00
35 800
35 o00
41 800
46 o00
56 o00
76 o00
4
5
6
7
8
8
10
10
10
12
15
15
higher force, is used to improve the weld soundness of

some aluminum alloys during the solidification of the
weld. The timing of application of forging force is very
critical. If applied too late, the weld will have already solidified, and no improvement will result. If applied too
soon, the sudden increase in contact area will lower the
resistance, possibly making the weld current insufficient
to allow a full size and strength weldto develop. The actual timing of the forging force may be determined by
measuring the weld force and current as a function of
time.
copper has high electrical and thermal conductivities but

is not heat treatable. I f higher strength electrodes are
needed, RWMA Group A, Class 2, copper electrodes
may be used. The lower electrical and thermal conductivities of the Class 2 copper alloy makes it less suitable for
welding aluminum except in those cases requiring higher
electrode strength or in combination with Class 1 electrodes to control weld penetration in dissimilar metal or
thickness combinations.
4 3 3 . 2 Net Electrode Force, Generally, the lower

strength, non-heat treatable aluminum alloys require less
electrode force than do the higher strength heat treatable
alloys.
Aluminum has higher shrinkage uponsolidification
than steel. Use of a low-inertia, low-friction welding
head assures rapid follow-up to reduce weld defects. In
seam welding, higher quality welds are produced with
indexing electrode wheels rather than with wheels turning during welding.
The variable force cycle, in which the weld is made at
a low force, followed by application of a carefully timed
4 3 3 3 Weld Time. Short weld times are desirable

when welding aluminum becauseof its high thermal conductivity. Thicker sheets require more weld time than
thinner sheets. Since short weld times are desired, the
rate of heat rise should be steep. However, excessively
high rates of heat rise will resultin porous, cracked welds,
or weld expulsion.
43.3.4 Weld Current. Higher currents are generally required for welding aluminum than steel and some
19

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
General Notes:
2. 'Qpesof aluminum alloy: 1 IO&H12-H18,300)3-H12H-H18,3OM-H32-H3X,5052-H32-H38,50150-H32-H3X,5356-H32-H38, 606l-T4-T6,6063-T5-T6.
3. A-C 60 Hz equipment.
AWS Cl.lM/Cl.l:2OOo
E
J
'Ea
a
nnn-nnnnnnhnhnnnnnnh
9999999999
9999999999
aaaasssss!=aaaassssss
2
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

20
AWSCI.IM/C1.1:2000
Table 18
Spot Welding Parameters for Aluminum
Alloys on Three-phase RectifierType Equipment
Electrode Diameter
and Shape'.2
RADIUS
-i
Sheet
Thickness
mm (in.)
5
I-D
mm (in.)
Radius
mm (in.)
15.9 (0.63) 76 (3.0)
1.27 (0.050)
1 . 6 0 (0.063)
1.80 (0.071)
2.03 (0.080)
2.29 (0.090)
2.54 (0.100)
3.18 (0.125)
15.9 (0.63)
15.9 (0.63)
15.9 (0.63)
22.2 (0.87)
22.2 (0.87)
22.2 (0.87)
22.2 (0.87)
Post
Weld
Forge
Weld
19.0
2.0 (450)
4.4 (980)
5.115.9
(1 150)
2.3 (520) 76 (3.0)
(0.63) 22.0
28.0
6.9 (1550) 3.0 (670)
76 (3.0) 15.9 (0.63)
8.0 (1800) 3.2 (730)
76 (3.0) 15.9 (0.63) 1.02 (0.040)
(900)
10.0 (2250) 4.0
203 (8.0)
12.9 (2900)
4.9 (1 100)
203 (8.0)
5.3 (1 190) 2031.44 (3240)
(8.0)
203 (8.0)
16.9 (3800) 6.5 (1460)
19.1 (4270) 7.6 (1710)
203 (8.0)
61.0
22.2 (4990)
8.5 (1910)
203 (8.0)
(8.0)
1 1 . 1 (2500) 203 28.9 (6500)
0.41 (0.016)
0.51 (0.020)
0.81 (0.032)
Welding Time4
(Approx.) (Approx.)
Cycles2 Amps
Welding Current3
Net Electrode Force
kN (Ib)'
Heat
Weld
1
None
None
None
30.0
36.0
38.0
42.0
45.0
49.0
54.0
32.0
37.0
43.0
48.0
52.0
56.0
7
8
9
69.0 10
Post
Heat
None
None
None 2 None
None
4 4
5
6 6
7
8
9
10
General Notes:
2. The top and bottom electrodes should have the same tip radius, or one has a radius tip and the other a flat tip.
3. The force and current values for alloys are 2014-T3, T4, Th, 2024-T3, T4,and 7075-Th. Somewhat lower values may be used for alloys such as
5052 and 6061.
4. A-C h0 Hz equipment.
Many of the alloys discussed in this section are precipitation-hardenable. For these alloys, a postweld heat treatment is usually needed to producea hardness in the weld
region similar to that of the alloy in the fully heat-treated
condition.
other metals because of its higher electrical and thermal

conductivities and low surface electrical resistance after
cleaning. Current sloping is frequently used on aluminum to control the cooling rate to reduce welddefects.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
4.4 Stainless Steels, Nickel, Nickel-Base Alloys, and

Cobalt-Base Alloys
4.4.1 Introduction. Mostof
these metalscanbe
readily resistance welded.The cast precipitation-hardenable
nickel-base alloys with low ductility are among those
that are normally difficult to resistance weld without
cracking.
An interesting phenomenon known as coring has been
observed in the heat-affected zone of resistance welds of
nickel-base alloys. The area may appear to resemble a
crack depending on the etching procedure and magnification. However, when it is properly etched and at enough
magnification, the area can beseen completely filled with
dendritic material as shown in Figure 2. Based on its dendritic structure, the area appears caused by either incipient melting or a crack which has been back-filled by the
molten weld metal. Coring can be reduced in some welds
by external water cooling during welding.
Figure 2"Coring in Nickel Alloy 718

(UNS N07718) Resistance Seam Weld, 200X
21


S T D = A W S C L - L H / C L = L - E N G L 2000
078q2b5 0513b77 521
AWS Cl .1 WC1 -1 :2000
Table 19
Spot Welding Parameters for Aluminum Alloys on Three-phase
Frequency Converter Type Equipment (Single Impulse Welds)
Electrode Diametcr and Shape
Net Electrode Force

kN (Ib)
Weld Current
(APProx-)
Amps x loo0
Radius
mm (in.)
mm (in.)
Weld
Forge
Weld
Post
Heat
15.9 (0.63)
7.9 (0.31)
76 (3.0)
254 (10.0)
2.2 (500)
2.7 (600)
2.2 (500)
5.3 (1 200)
26
None
19
4.0
MIL^
15.9 (0.63)
7.9 (0.31)
76 (3.0)
254 (10.0)
2.2 (500)
2.7 (600)
5.3 (1 200)
7.1(1 600)
34
25
0.81 (0.032)
CO"'
MILz
15.9 (0.63)
9.5 (0.37)
102 (4.0)
254 (10.0)
2.7 (600)
3.1 (700)
5.8 (1 300)
8.0 (1 800)
1.02 (0.040)
CO"'
MILZ
15.9 (0.63)
9.5 (0.37)
102 (4.0)
254 (1 0.0)
3.1 (700)
3.6 (800)
1.27 (0.050)
COM"
15.9 (0.63)
11.1 (0.44)
102 (4.0)
254 (10.0)
15.9 (0.63)
12.7 (0.50)
MIL^
Sheet Thickness
mm (in.)
0.51 (0.020)
COMML
8.5
6.3
1
1
3
2
36
30
9.0
7.5
1
1
4
2
6.7 (1 500)
8.9 (2 OOO)
42
40
12.6
12.0
1
2
4
4
3.6 (800)
4.0 (900)
8.0 (I 800)
10.2 (2 290)
46
43
13.8
12.9
1
2
5
4
152 (6.0)
254 (10.0)
4.4 (1 000)
5.8 (1300)
8.9 (2 000)
13.3 (2 990)
54
51
18.9
2
3
5
6
15.9 (0.63)
15.9 (0.63)
152 (6.0)
254 (10.0)
5.3 (1200)
7.1 (1600)
11.1 (2500)
16.0 (3 600)
61
57
20.0
2
3
6
6
CO"'
MILZ
22.2 (0.87)
15.9 (0.63)
152 (6.0)
254 (1 0.0)
6.2 (1400)
8.0 (1800)
12.5 (2 810)
18.2 (4 OW)
65
63
22.8
22.1
3
4
COMM~
22.2 (0.87)
15.9 (0.63)
152 (6.0)
254 (1 0.0)
7.1 (1600)
.0.7 (2400)
14.2 (3 1W)
23.6 (5 310)
75
73
30.0
29.2
3
4
8
8
MIL^
22.2 (0.87)
22.2 (0.87)
203 (8.0)
254 (10.0)
8.9 (2000)
2.5 (2810)
17.8 (4 OOO)
30.2 (6 790)
85
81
34.0
32.4
3
5
8
10
COM"
MIL*
22.2 (0.87)
22.2 (0.87)
203 (8.0)
254 (10.0)
!O.O (4500)
22.2 (4 990)
44.5 (10 OOO)
100
100
45 .O
45 .O
4
5
10
10
COM"
COM"
MIL^
1.80 (0.071)
2.03 (0.080)
2.29 (0.090)
COM"
MIL^
2.54 (0.100)
3.18 (0,125)
Post
Heat
None
MIL^
1.60 (0.063)
Weld
1i 2
1
MIL^
0.64 (0.025)
Welding Time
Cycles
(60per sec.)
CO"'
7.8 (4000)
17.9
21.4
General Notes:
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
1 . COMM = commercial requirements.

2. M I L = military requirements.
22

AWS C l .i
M/C1.1:2000
(1) Plate the faying surfaces with a higher electrical

resistance metal (e.g., tin or nickel), to compensate for
the low electrical resistance of the base metal. This technique can greatly improve the resistance weldability of
copper. However, since the plating will alter the chemical
composition of the weld, itsacceptability should be evaluated based on the service requirements of the welded
joint.
(2) Use electrodes faced with a refractory metal like
tungsten or molybdenum (e.g., RWMA Group B, Classes
13 and 14), to reduce alloying and sticking of the electrodes to the workpiece.
(3) Use a short weld time to minimize metal expulsion and sticking of the electrode to the workpiece.
(4) Because of the narrow plastic range of copper and
copper alloys, use machines with a low-inertia welding
head. This provides faster follow-up to maintainpressure
on the joint to prevent metalexpulsion.
4.4.2 Surface Condition. The surfaces to be welded

should be clean, and free of contaminants that can cause
inconsistent welds. In addition, some contaminants might
contain a low-melting-point element such as sulfur or
lead that can cause hot-cracking in the welds. Machined
surfaces and mill descaled rolled-sheet surfaces may be
welded after solvent or vapor degreasing. Some solvents
are toxic and breathing the fumes can cause dizziness.
Other solvents are flammable and require good ventilation; therefore, proper precautions should be taken.
4.43 Weld Parameters. The data shown in Tables 20
through 37 are offered as a guide to develop welding
schedules for stainless steels, nickel, nickel-base
and cobaltbase alloys. The following sections are comments and
discussions pertaining to these tables. Additional comments and discussions applicable to the above metals are
presented separately in 4.7.
4.43.1 Electrodes. Most of these metalsretain
their high strength at elevated temperatures. Therefore,
electrodes for resistance welding these metals are usually
RWMA Group A, Class 2 or 3 copper alloy (see Table 8).
These copper alloys are age-hardenable and thus have
higher strength than RWMA Group A, Class 1, which are
not heat treatable.
4.6 Titanium and Titanium Alloys.Titanium and its alloys can be readily resistance welded. Although they are
highly sensitive to embrittlement caused by reaction with
air at fusion-welding temperatures, inert-gas shielding is
not required because the surrounding base metal protects
the molten weld metal from air contamination.
Before welding, the surfaces should be clean. Foreign
substances can adversely affect the weld consistency. In
addition, some can contaminate the welds with such interstitial elements as hydrogen, carbon and oxygen.
Increases in the concentration of these elements can significantly decrease the weld ductility and toughness.
Scale-free surfaces may be welded after degreasing or
after degreasing plus pickling. Pickling may be carried
out in a water solution containing 2 to 5 percent hydrofluoric acid and 30 to 40 percent nitric acid by volume.
Pickling acid, hydrofluoric acid and nitric acid are hazardous to the skin and eyes. Hazardous fumes can be produced by these acids and violent chemical reactions can
result when acids are mixed with other chemicals, especially those with basic pHs. Acids can also eat through
some clothing. Use precautions when working near or
with acids. Strict precautions are necessary in their use
and disposal. Acids should be added to water, not water
into acid. Pickling, hydrofluoric and nitric acids cause
chemical burn to the skin. Mix and use pickling acid in a
properly vented area. Before use, read and understand
the manufacturers instructions, Material Safety Data
Sheets (MSDSs), and your employers safety practices.
Rinse the surfaces in clean water and dry them after
pickling.
The data shown in Table 39 may be used as a guide
to develop spot welding schedules for titanium alloy
4.43.2 Net Electrode Force. A higher electrode

force is needed for most of these metals as compared
with carbon steels.
4.433 Dissimilar Alloys. When dissimilar alloys
of similar thicknesses are welded, penetration of the
weld nugget into one alloy may be less than into the
other alloy because of differences in melting points and
thermal and electrical conductivities. For example, when
Type 321 stainless steel is welded to nickel alloy 718,
penetration into the stainless steel will be less than that
into the nickel alloy 718. Penetration into the stainless
steel can be increased by installing an electrode with either a lower thermal conductivity or smaller face area, or
both, on the stainless steel side. The lower thermal conductivity or smaller face decreases the heat conducted
away from the stainless steel by the electrode. A smaller
face area will also concentrate the weld current or heat
into a smaller area.
4.5 Copper and CopperAlloys. Copper and copper alloys can be resistance spot welded although copper and
some of the copper alloys have very high electrical and
thermal conductivities. Electrical and thermal conductivities are among the properties of a metal that can significantly affect its resistance weldability. The data shown in
Table 38 may be used as a guide to develop spot welding
schedules for various copper alloys. The following techniques may be used to facilitate resistance spot welding
of these metals:
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

6%AI-4%V.
23
S T D - A W S C L * L N / C L * L - E N G L 2000
07Bq2b5 1533b79 3 T 9
O
U ,
24
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


S T D - A W S C L ~ L M / C I I - L - E N G L 2000
= 0 7 8 V 2 b 5 0513680 OLb D
AWS C l .1M/C1.1:2000
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
I B
u n
25

STD-AWS C L - b M / C L - L - E N G L Z O O 0 W 078q2b5 0513bBL T 5 2

AWS Cl .1M/CI.1:2000
Table 22
Seam Welding Parameters for Stainless Steels
Electrode Width
and Shape*
Off Time
@(3 in.)mm
76
Sheet
Thickness
mm (in.)
0.15 (0.006)
0.20 (0.008)
0.25 (0.010)
0.30 (0.012)
0.36 (0.014)
0.41 (0.016)
0.46 (0.018)
0.53 (0.021)
0.64 (0.025)
0.78 (0.031)
1.O2 (0.040)
1.27 (0.050)
1.57 (0.062)
1.78 (0.070)
1.98 (0.078)
2.39 (0.094)
2.77 (0.109)
3.18 (0.125)
4-4
RADIUS
Minimum
Contacting
Overlap5
mm (in.)
Net
Electrode
W
mm (in.)
Force
kN (Ib)
4.8 (0.19)
4.8 (0.19)
4.8 (0.19)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
9.5 (0.37)
9.5 (0.37)
9.5 (0.37)
12.7 (0.50)
12.7 (0.50)
15.9 (0.63)
15.9 (0.63)
15.9 (0.63)
19.0 (0.75)
19.0 (0.75)
1.33 (300)
1.56 (350)
1.78 (400)
2.00 (450)
2.22 (500)
2.67 (600)
2.89 (650)
3.1 1 (700)
3.78 (850)
4.45 (1000)
5.78 (1 300)
7.12(1600)
8.23 (1 850)
9.56 (2150)
10.23 (2300)
1 1.34(2550)
26.47 (5950)
14.68 (3300)
On
Time
Cycles4
2
2
3
3
3
3
3
3
3
3
3
4
4
4
for
Maximum Maximum
Speed
Weld
(PrcssureSpeed
Tight)
m/min
Cycles4
(in./min)
1
2
2
2
2
2
2
3
3
4
4
5
5
6
6
7
6
4
5
5
6
1.5 (60)
1.7 (67)
1.1 (45)
1.2 (48)
1.3 (51)
1.3 (51)
1.4 (55)
1.4 (55)
1.3 (51)
1.3 (51)
1.2 (47)
1.1 (45)
1.o (40)
1.1 (45)
1.o (40)
0.9 (35)
1.o (40)
1.o (40)
Welds
Per
Meter
(in.)
510 (20)
460 (18)
410 (16)
380 (1 5)
360 (14)
360 (14)
330 (1 3)
330 (13)
300 (12)
300 (12)
280 (11)
250 (10)
250 (10)
230 (9)
230 (9
230 (9)
200 (8)
200 (8)
Welding
Current
(APPrOx.)
Amps
4000
4600
5000
5600
6 200
6 700
7 300
7900
9 200
10 600
13 000
14 200
15 100
15 900
16 500
16 600
16 800
17 000
+ILI+
&i9
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
7.9 (0.31)
7.9 (0.31)
7.9 (0.31)
7.9 (0.31)
9.5 (0.37)
11.1 (0.44)
11.1(0.44)
12.7 (0.50)
15.9 (0.63)
15.9 (0.63)
17.5 (0.69)
17.5 (0.69)
19.0 (0.75)
20.6 (0.81)
22.2 (0.87)
General Notes:
1 . Types of steel-301,302,303,304,308, 309,310,316,317,321,347, and 349.
3. For large assemblies, minimum contacting overlap indicated should be increased30 percent.
4. A-C 60 Hz equipment.
4.7 Welding Data Comments and Discussions Applicable to Various Metals. The following comments and
discussions are applicable to the spot and seam welding
data for all of the following:
(1) Uncoated carbon and HS steels
(2) Coated carbon and HS steels
(3) Aluminum alloys
(4) Stainless steels, nickel, nickel-base alloys, and cobaltbase alloys
( 5 ) Copper and copper alloys
(6) Titanium and titanium alloys
4.7.1 Spot Welding Electrode Face Diameter. The
electrode face diameter affects the electrode pressure and
current density experienced by the weld nugget being
formed. Face diameters greater than those recommended
in the tables will reduce current density and electrode
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

pressure. Similar results occur when the electrode face

diameter increases in size during welding due to wear
and deformation. Electrode face diameters smaller than
those recommended may result in expulsion, excessive
indentation or electrode sticking. Electrode face diameters other than those presented in the tables may be used.
However, the welding schedule must be adjusted accordingly (see Figure 1 and Table 40).
Care should be exercised to preventexcessive increase
or decrease in the face diameter during electrode dressing. Where a flat-face electrode is used, the face diameter
should not exceed the value given in order to control the
electrode contact area.
4.7.2 Electrode Face Width (Seam Welding). Electrode wheels are used in seam welding. Therefore, electrode face width, rather than electrode face diameter, is
specified in seam welding.
26
AWS Cl.lM/C1.1:2000
Table 23
Spot Welding Parametersfor Annealed Nickel-Copper Alloy3on Single-phase Equipment
Electrode Diameter
and Shape'*2
Minimum
:ontacting
Overlap
mm (in.)
Sheet
Thicknesses
mm (in.)
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
0.13 (0.005) to:

0.13 (0.005)
0.25 (0.010)
0.38 (0.015)
0.53 (0.021)
d
mm (in.)
Max.
D
mm (in.)
Min.
4.0 (0.16)
4.0 (0.16)
4.0 (0.16)
4.0 (0.16)
4.0 (O. 16)
4.0 (0.16)
4.0 (0.16) 6.4 (0.25)
7.9(0.031)
(0.31)
4.0 (0.16) 0.78
1.60 (0.063) ' 4.0 (O. 16) 16.0 (0.63)
2.36 (0.093)
4.0 (0.16) 16.0 (0.63)
4.0 (O. 16) 16.0 (0.63)
3.18 (0.125)
0.25 (0.010) to:
0.25 (0.010) 4.0 (O. 16) 4.0 (0.16)
4.0 (O. 16) 4.0 (0.16)
0.38 (0.015)
4.0 (0.16)
4.0 (0.16)
0.53 (0.021)
0.78 (0.031)
4.0 (O. 16) 4.0 (0.16)
4.0 (O. 1 6) 7.9 (0.31)
1.60 (0.063)
2.36 (0.093) 4.0 (O. 16) 16.0 (0.63)
3.18 (0.125) 4.0 (O. 1 6) 16.0 (0.63)
0.38 (0.015) to:
4.8 (0.19)
0.38 (0.0 15) 4.8 (0.19)
0.53 (0.021)
4.8 (0.1 9) 4.8 (O. 19)
4.8 (0.19)
4.8 (0.19)
0.78 (0.031)
1.60 (0.063) 4.8 (O. 19) 16.0 (0.63)
2.36 (0.093) 4.8 (0.19) 16.0 (0.63)
3.18 (0.125) 4.8 (O. 19) 16.0 (0.63)
0.53 (0.021) to:
0.53 (0.021) 4.8 (0.19) 4.8 (0.19)
0.78 (0.031) 4.8 (O. 19) 4.8 (0.19)
4.8 (0.19:
1.60 (0.063) 4.8 (0.19)
4.8 (O. 1 9) 16.0 (0.63;
2.36 (0.093)
4.8 (0.19) 16.0 (0.63;
3.18(0.125)
0.78 (0.031) to:
0.78 (0.031) 4.8 (O. 19) 4.8 (0.19;
1 .60 (0.063) 4.8 (0.19) 6.4 (0.25:
4.8 (0.19) 16.0 (0.63:
2.36 (0.093)
3.18 (0.125) 4.8 (O. 1Y) 16.0 (0.63:
1.60 (0.063) to:
7.9 (0.31:
1.h0 (0.063) 7.9 (0.31)
2.36 (0.093) 7.9 (0.31) 16.0 (0.63:
3.18 (0.125) 7.9 (0.31) 16.0 (0.63:
2.36 (0.093) to
9.5 (0.37:
2.36 (0.093) 9.5 (0.37)
9.5 (0.37:
3.18 (0.125) 9.5 (0.37)
3.18 (0.125) to
3.18 (0.125) 12.7 (0.50) 12.7 (0.50
Net
Electrode
Force
kN (Ib)
Weld
Time
Cycles
Welding
Current
,Approx.)
Amps
*I L I" Minimum
Weld
Spacing
&9
Qto
mm (in.)
Nugget
Diameter
mm (in.)
I+Do
Minimum
Shear
Strength
kN (Ib)
."J
CI
5000
6 100
7000
7 200
7400
8000
8600
8 700
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
4.8 (0.1 9)
7.9 (0.31)
7.9 (0.31)
1 1.1 (0.44)
12.7 (0.50)
12.7 (0.50)
2.5 (0.10)
2.5 (0.10)
2.5 (0.10)
2.8 (0.1 1)
2.8 (0.1 1)
2.8 (0.1 1)
2.8 (0.11)
2.8 (0.1 1)
0.24 (55)
0.27 (60)
0.33 (75)
0.38 (85)
0.42 (95)
0.40 (W)
0.40 (W)
0.42 (95)
4
4
4
4
7 200
8 600
8 200
8 800
9 200
9 900
9 Y00
6.4 (0.25)
6.4 (0.25)
6.4 (0.25) 7.9 (0.31)
6.4 (0.25) 7.9 (0.31)
7.9 (0.31)
6.4 (0.25)
7.9 (0.31)
6.4 (0.25)
6.4 (0.25) 12.7 (0.50)
6.4 (0.25) 12.7 (0.50)
3.0 (O. 12)

3.0 (0.12)
3.3 (0.13)
3.3 (0.13)
3.3 (0.13)
3.6 (0.14)
3.6 (0.14)
0.64 (140)
0.69 (155)
0.76 (170)
0.85 (190)
0.85 (1 90)
0.93 (210)
0.98 (220)
1.33 (300)
1.33 (300)
1.45 (330)
1.45 (330)
1.45 (330:
1.45 (330:
2
6
6
6
8
8
8 600
8 200
Y 300
9 400
9 500
9 500
7.9 (0.31)
6.4 (0.25)
6.4 (0.25) 9.5 (0.37)
6.4 (0.25) 9.5 (0.37)
6.4 (0.25) 11.1 (0.44)
6.4 (0.25) 12.7 (0.50)
6.4 (0.25) 12.7 (0.50)
3.3 (0.13)
3.3 (O. 13)
3.3 (O. 13)
3.6 (O. 14)
3.6 (0.1%
3.6 (0.14:
1.11 (250)
1.31 (290)
1.33 (300)
1.56 (350)
1.60 (360)
1.62 (364)
1.33 (300:
1.45 (330:
1.45 (330:
1.45 (330:
1.45 (330:
12
12
12
12
12
6 200
6 800
7 200
7 700
8 200
7.9 (0.31)
7.9 (0.31)
7.9 (0.31)
9.5 (0.37)
9.5 (0.37)
11.1 (0.44)
11.1 (0.44)
12.7 (0.50)
14.3 (0.56)
14.3 (0.56)
3.3 (0.13:
3.3 (0.13:
3.6 (0.14:
3.6 (0.14
3.6 (0.14
2.00 (450)
2.05 (460)
2.22 (500)
2.36 (530)
2.45 (550)
3.1 1 (700:
3.34 (750'
3.45 (780
3.45 (780
12
12
12
12
10 500
11 200
11 400
1 I 800
9.5 (0.37)
12.7 (0.50)
12.7 (0.50)
12.7 (0.50)
16.0 (0.63)
17.5 (0.69)
19.0 (0.75)
19.0 (0.75)
4.3 (0.17
4.6 (0.18
4.8 (0.19
4.8 (0.19
3.76 (845)
4.05 (910)
4.60 (1034)
4.78 (1075)
2.01 (27M
12.0 1 (27M
12.01 (27M
12
12
12
15 300
15 900
16 200
16.0 (0.63) 28.6 (1.13)

16.0 (0.63: 30.2 (1.19)
16.0 (0.63: 31.8 (1.25:
7.9 (0.3 1
7.9 (0.31
8.1 (0.32
9.16 (2060)
9.70 (2180)
10.50 (2360)
12.28 (276(
12.28 (276(
20
20
22 600
25 O00
19.0 (0.75: 31.8 (1.25;

19.0 (0.75: 31.8 (1.251
9.4 (0.37
9.7 (0.38
17.26 (3880)
19.53 (4390)
!2.24 (500(
30
30 000
22.2 (0.87:
41.3 (1.63:
11.9 (0.47
26.02 (5850)
0.98 (220)
0.98 (220)
0.98 (220)
0.98 (220)
1.11 (250)
1.11 (250)
1.11(250)
1.11 (250)
1-20(270)
1.25 (280)
1.25 (280)
1.33 (300)
1.33 (300)
1.45 (330)
1.45 (330)
2
2
2
2
3
4
4
4
4
General Notes:
1. Electrode shape may be flat rather than domed, in which case the shear strengths and nugget diameters will be higher and larger than shown in the
lable.
2. Electrode material: R W M A Class 1 or Class 2.
3. Nominal chemical composition of nickel-copper alloy (UNS N04400), wt.-%: 66.0 Ni, 31.5 Cu, 1.35 Fe, 0.90 Mn, 0.15 Si, 0.12 C, 0.005 S .
27

~~
S T D = A W S C L * L M / C L = L - E N G L 2000 07842b505L3b83
825
AWSCl.lM/C1.1:2000
-3.d
EE
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


STDmAWS C l = l M / C l - l - E N G L 2000 D 078112b5 O 5 l 3 b A 4 7 b l D

AWS Cl .1M/C1.1:2000
Table 25
Seam Welding Parameters for Annealed Nickel-Copper Alloy
on Single-phase Equipment
Electrode Wheel
Width and Shape2
Off Time
Net
Sheet
Thickness
mm (in.)
0.25 (0.010)
0.38 (0.015)
0.53 (0.021)
0.64 (0.025)
0.79 (0.031)
1.57 (0.063)
(Pressure
Tight)
Cycles
Radius
mm (in.)
76 (3.0)
152
152
152
152
152
(6.0)
(6.0)
(6.0)
(6.0)
(6.0)
Minimum
Contacting
Overlap
mm (in.)
13.3 (300)
22.2 (500)
2.67 (600)
3.11 (700)
11.1 (2500)
Welding
Current
(Approx.)
Amps
3
6
5 300
7 600
8 700
12
12
12
Y 500
10 O00
19 O00
-I
r-
n
u
&
J
J&
,,
6.4 (0.25)
6.4 (0.25)
7.9 (0.31)
7.9 (0.31)
9.5 (0.37)
16.0 (0.63)
General Notes:
1. Nominal chemical composition of nickel-copper alloy (UNS N04400), wt.-%: 66.0 Ni, 31.5 Cu, 1.35 Fe, 0.90 Mn, 0.15 Si, 0.12 C, 0.(H)5S.
2. Electrode material: RWMA Class 2 (Preferred) or Class 1.
4.73 ElectrodeFaceShape.
The electrode face
shape influences the weld size, shape and surface indentation. To maintain consistent weld quality, the electrodes may require redressing after a limited number of
welds to maintain their geometric shape and proper face
area, and to minimize contact resistance between the
work and electrode.
For special combinations, such as unequalthicknesses, it is often desirable to use a combination of electrode shapes or contours to produce acceptable welds.
Generally, a smaller radius contour, which produces
greater concentration of weld heat, will produce higher
weld penetration in the sheet contacting it. Conversely, a
larger radius contour, which produces less concentration
of heat, will produce lower weld penetration in the sheet
contacting it.
Standard RWMA nose or tip geometries of spot welding electrodes are shown in Figure 1.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
(95F). For adequate cooling, a maximum electrode face

thickness (nose thickness) of 13 m m (0.50 in.) with a
properly positioned coolant inlet tube is recommended.
The coolant inlet tubeshould be cut on an angle at the tip
and inserted tocontact the bottomof the water holein the
electrode to ensure maximum cooling of the face. If the
coolant inlet tube is not properly placed, steam or turbulence may develop within theelectrode tip, reducing heat
dissipation. The reduced cooling of the electrode will decrease the electrode life.
External water cooling may be used in combination
with internal water cooling to provide more effective
cooling of the spot welding electrodes.
In seam or roll-spot welding, thewheel electrode
should be cooled with an external water stream directed
at the weld area, cooling both the electrode and workpiece, where practical.
4.7.5 Net Electrode Force. Correct weld forces, for a

given combination of current level and weld time, are required to produce welds of optimum nugget size and
penetration without expulsion, porosity, cracking, or excessive indentation. Excessively low forces do not provide current uniformity and molten metal containment,
and may result in expulsion at the joint or electrode-toworkpiece interface. Excessively high forces produce
4.7.4 Electrode Cooling.Spot and projection welding

electrodes should be internally water cooled to prevent
overheating which results in electrode sticking and decreased electrode life. Internal coolant flow rate requirements may vary from 1.9 to 5.7 Umin (0.5 to 1.5 gal/min)
per electrode, depending on the type of welding system.
Water coolant temperature should be less t h a n 35C
29

AWS Cl.lM/C1.1:2000
30
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


AWS Cl ,1 M/C1.1:2000
Table 27
Spot Welding Parameters for Annealed Nickel-Chromium
Alloy 6003 on SinglePhase Equipment
~
Electrode Diameter
and S h a ~ e ' . ~ . ~
Ainimum
bntacting
Overlap
mm (in.)
RADIUS
Sheet
Thicknesses
mm (in.)
0.13 (0.005) to:
O. 13 (0.005)
0.25 (0.010)
0.38 (0.015)
0.53 (0.021)
0.79 (0.031)
1.6
(0.063)
2.4
(0.093)
3.2
(0.125)
0.25 (0.010) to
0.25 (0.010)
0.38 (0.015)
0.53 (0.021)
0.79 (0.031)
1.6
(0.063)
2.4
(0.093)
3.2
(0.125)
0.38 (0.015) to
0.38 (0.0 15)
0.53 (0.021)
0.79 (0.031)
1.6
(0.063)
2.4
(0.093)
3.2
(0.125)
0.53 (0.021) to
0.53 (0.021:
0.79 (0.031:
1.6
(0.063:
2.4
(0.093:
3.2 (0.125;
0.79 (0.031) tc
0.79 (0.031'
1.6(0.063:
2.4
(0.093:
3.2
(0.125:
1.6(0.063)
tc
1.h (0.063,
2.4
(0.093'
3.2
(0.125
2.4(0.093) tc
2.4
(0.093
3.2 (0.125
3.2(0.125) tc
3.2
(0.125
&
7000
5 300
5 500
4 800
5 400
5 600
5 800
5600
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
4
4
6
6
6
6
6
7900
5 500
5 loo
5600
5 500
5 800
4 600
1 .h0 (360)
1.60 (360)
I .78 (400)
1.78 (400)
1.78 (400)
1.78 (400)
6
6
8
8
10
12
1.34 (300)
1.56 (350)
1.78 (400)
2.22 (500)
2.45 (550)
3.11 (700)
3.11 (700)
3.11 (700)
3.34 (750)
Net
Electrode
Force
-CI
CI +Da
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
7.9 (0.31)
7.9 (0.31)
9.5 (0.37)
9.5 (0.37)
9.5 (0.37)
2.8 (0.11)
3.0 (O. 12)
3.0 (0.12)
3.3 (0.13)
3.3 (O. 13)
3.8 (0.15)
4.1 (0.16)
3.8 (O. 15)
0.3
(700)
0.44 (100)
0.47 (106)
0.49 (110)
0.53 (120)
0.60 (130)
0.65 (150)
0.60 ( 130)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
7.1 (0.28)
7.1 (0.28)
7.9 (0.31:
9.5 (0.37)
9.5 (0.37:
3.0 (O. 12)

3.3 (O. 13)
3.3 (O. 13)
3.3 (0.13)
3.6 (0.14)
3.8 (O. 15)
3.6 (0.14)
0.78 (175)
0.96 (220)
0.96 (220)
1.29 (290)
1.40 (315)
1.56 (350)
1.65 (370)
7 600
8 400
4 600
4 700
4 700
4 600
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25)
6.4 (0.25:
6.4 (0.25:
7.1 (0.28:
7.9 (0.3 1:
8.7 (0.34'
9.5 (0.37:
3.0 (0.12)
3.0 (0.12)
3.3 (O. 13)
3.3 (0.13)
4.1(0.16)
4.1 (O. 16)
1.31 (294)
1.29 (2%)
1.65 (370)
1.96 (440)
2.38 (535)
2.49 (560)
12
12
12
12
12
4000
4 100
5 300
5900
6 300
7.9 (0.31)
7.9 (0.31)
7.9 (0.31)
7.9 (0.31)
7.9 (0.31)
11.1 (0.44
11.1 (0.44
11.9 (0.47
12.7 (0.50
12.7 (0.50
3.0 (0.12)
3.0 (0.12)
3.0 (0.12)
3.8 (O. 15)
3.8 (0.15)
2.42 (544)
2.38 (535)
2.58 (580)
2.98 (670)
3.07 (690)
12
12
12
12
6 700
7 100
8 300
8 900
9.5 (0.37)
9.5 (0.37:
9.5 (0.37:
9.5 (0.37:
14.3 (0.56
16.0 (0.63
17.5 (0.69
19.0 (0.75
4.6 (0.18)
4.6 (0.18)
5.1 (0.20)
5.1 (0.20)
4.09 (Y20)
4.29 (964)
5.74 (1 290)
5.38 (1210)
D
mm (in.)
Min.
4.0 (O. 16)

4.0 (O. 16)
4.0 (O. 16)
4.0 (O. 16)
4.0 (0.16)
4.0 (O. 16)
4.0 (O. 16)
4.0 (O. 16)
4.0 (O. 1 6)
4.8 (O. 19)
4.8 (0.19)
4.8 (0.19)
4.8 (0.19)
16.0 (0.63)
16.0 (0.63)
16.0 (0.63)
1.34 (300)
1.34 (300)
1.34 (300)
1.34 (300)
1.45 (326)
1.45 (326)
1.45 (326)
1.45 (326)
2
4
4
6
6
6
6
6
4.0 (O. 16) 4.8 (0.19)

4.0 (O. 16) 4.8 (0.19)
4.0 (O. 16) 4.8 (0.19)
4.0 (O. 16) 4.8 (O. 19)
4.0 (0.16) 4.8 (0.19)
4.0 (0.16) 16.0 (0.63)
4.0 (0.16) 16.0 (0.63)
1.42 (320)
1.42 (320)
1.42 (320)
1.56 (350)
1.78 (400)
1.78 (400)
1.78 (400)
kN (Ib)
4.8 (0.lY)
4.8 (O. 19)
4.8 (O. I Y)
7.9 (0.31)
16.0 (0.63)
16.0 (0.63)
4.8 (O. 19: 4.0 (O. 16)

4.8 (O. 1 9)
4.8 (0.1 Y'
4.8 (O. 19 4.8 (O. 191
4.8 (O. 1!I 16.0 (0.631
4.8 (O. 19: 16.0 (0.63)
c'
Nugget
Diameter
mm (in.)
Minimum
Shear
Strength
kN (Ib)
Neid
rime
:ycles
d
mm (in.)
Max.
4.8 (O. 1 Y]
4.8 (0.19;
4.8 (0. 19;
4.8 (O. 19:
4.8 (0.19;
4.8 (0.19;
r-
Winimum
Weld
Spacing
(to.(
mm (tn.)
*I L
Welding
Current
Approx.)
Amps
4.8 (0.19
4.8 (O. 19
4.8 (O. 19
4.8 (0.19
4.8 (0.19)
7.9 (0.3 1
9.5 (0.37;
16.0 (0.63)
4.8 (O. I Y
7.9 (0.31
14.3 (0.56
9.21 (2070
7.9 (0.3 1
16.0 (0.63: 10.90 (2450
16.0 (0.63: 1 1.57 (2600
12
16
20
12 o00
12 000
12 o00
16.0 (0.63; 28.6 (1.13

16.0 (0.63: 30.2 (1.19
16.0 (0.63: 31.8 (1.25
7.9 (0.3 1)
7.9 (0.31)
8.1 (0.32)
12.41 (2790)
12.23 (2750)
15.21 (3420)
9.5 (0.37
11.1 (0.44
9.5 (0.37 17.21 (3870

11.1 (0.44: 22.69 (5 1O0
20
30
19 o00
20 O 0 0
19.0 (0.75: 30.2 (1.19

19.0 (0.75: 31.8 (1.25
9.4 (0.37)
10.2 (0.401
19.57 (4400)
20.91 (4700)
11.1 (0.44
11.1 (0.44 23.44 (5270
30
20 100
22.2 (0.87
33.3 (1.31
1 1.1(0.44: 28.47 (6400)
General Notes:
1. Electrode shape may be flat rather than domedin which ca..e the shear strengths and nugget diameterswill be higher and larger than shownin the table.
2. Electrode material: R W M A Class 2, Class 3. or Class 4.
3. Nominal chemical composition of nickel-chromium alloy 600 (UNS 066(H)),wt.-%: 76.0 Ni, 15.8 Cr, 7.20 Fe, 0.04 C, 0.20 Mn, 0.10 Cu, 0.04 C,
O.tM)7 si.
4. Indicates molybdenum-tipped electrode.
31
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
. .
E3
32

AWS Cl.lM/C1.1:2000
U)
o)
.-cC
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
v)
2
d
O P
f?
aE. g
EE
E
33

U)
o)
E
o
z
.-z
4-
o)
K
Y
I d
n
F
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
mo)
Q)
ul
.-C
I!
s"
CI
P
v)
34

S T D = A W S C L = L M / C L - L - E N G L 2000
078q2b5 0 5 L 3 b 7 0 T b 5
AWSCl.lM/C1.1:2000
Table 31
Seam Welding Parametersfor Annealed Nickel-Chromium
Alloy X7503 on Single-phase Equipment
Electrode Wheel Width
and Shape'**
Minimum
Contacting
Overlap
mm (in.)
I
Sheet
Thickness
W
mm (in.)
Min.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
6.4 (0.25)
0.38 (0.015 ) 6.4 (0.25)
0.53 (0.021)
9.5 (0.37)
0.79 (0.031) 9.5 (0.37)
1.57 (0.062) 12.7 (0.50)
Net
E
mm (in.)
Max.
mm (in.)
Electrode
Force
kN (Ib)
3.2 (0.13)
3.2 (0.13)
5.6 (0.22)
4.8 (0.19)
4.8 (0.19)
76 (3.0)
76 (3.0)
76 (3.0)
76 (3.0)
152 (6.0)
1.8 (400)
3.1 (700)
6.2 (400)
10.2 (2300
17.8 (4000
Radius
Welding
On
(Pressure Speed
Welds pel Current
mm/min
Time
Tight)
Meter (APProx-)
Amps
(in.)
Cycles Cycles (in./min)
1
2
3
4
8
Off Time
Weld
3
4
6
8
16
11 4 0 (45)
910 (36)
760 (30)
760(30)
300 (12)
3 m
790 (20)
670 (1 7) 3900
8OOO
550 (1 4)
8 500
470 (12)
10 300
390 (10)
+LI"
4.8 (0.19)
6.4 (0.25)
7.9 (0.31)
9.5 (0.37)
9.5 (0.37)
General Notes:
1. Electrode material: RWMA Class 2 or Class 3.
2. Class 2 preferred for 0.54,0.38, and 0.53 mm (O.OlO,O.015, and 0.021 in.) thicknesses; for 0.7Y and 1.57 mm (0.031 and 0.062 in.) thicknesses,
C1a.s 2 or 3 is suiVdble.
3. Nominal chemical composilion of nickel-chromium alloy X750 (UNS N07750), wt.-%:73.0 Ni, 15.5 Cr, 6.75 Fe, 2.50 Ti, 0.85 Cb, 0.80 Al, 0.70
Mn, 0.05 Cu,0 . 0 4 C , 0.030 Si, 0.007 S .
4.7.6 Weld Schedule Times. Properly set times contribute to high quality resistance welding. The values
shown for all times are in cycles based on 60 cycles per
second. Some of the time variables discussed below are
usually part of the welding schedules, but are not necessarily shown in the tables.
metal indentation, distortion, and a small weld nugget diameter. As the electrode force increases, the resistance
values of the workpiece circuit will decrease. Lower resistance values require higher current levels in order to
provide proper heating of the faying interface to create a
proper weld nugget. Therefore, a correct balance of current, weld time, and electrode force is necessary. Electrode alignment is necessary for proper weld force
application. Nonparallel electrode faces can result in a
limited electrode tip contact area which will experience a
large effective weld pressure. The non-uniform application of weld force may result in excessive surface indentation, localized overheating, expulsion, or undersized
weld nuggets. Non-vertically aligned electrodes may
produce similar results. Further, electrode wear may alter
the effective electrode pressure if the electrode face area
increases or decreases.
When a forging force is employed topreventweld
nugget cracking in resistance seam welding, an intermittent drive is used so that the forging force is applied
directly over the intended weld nugget. When an intermittent drive is used, theelectrode wheels are stopped for
each weld nugget.
4.7.6.1 Squeeze Time. This time includes allowances for delays in valve shifting, mechanical movement
of the weld head to the work, thecomplete pressurization
of the cylinder, and the bringing of the pieces to be
welded into intimate contact. Inadequate squeeze time
results in inconsistent weld quality.
4.7.6.2 Weld Time. Proper weld times are based
upon current and electrode force values chosen for the
materials being joined. Longer or shorter weld times may
result in inconsistent weld quality.
4.7.6.3 Hold Time. The electrode provides a continued force to the weld nugget, and cools the workpiece
as long as pressure is maintained. The number of cycles
of hold time needed varies with material and thickness.
Actual hold time is usually severalcycles longer than the
specified hold time because of mechanical delays.
35

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
AWS Cl .lMICl
.1:2000
xxx I I I
I I
ln
14-44
I 123%
m
o
36

STDmAWS C L = L M / C L * L - E N G L 2000
078112b5 0513b72 838 W

AWSCl.lM/C1.1:2000
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
37

Table 34
Spot Welding Parameters for Annealed Nickel on Single-phase Equipment
Electrode Diameter
and Shape'**
Minimum
Contacting
Overlap
mm (in.)
Sheet
Thickness
mm (in.)
d
in.
Max.
D
in.
Min.
Net
Electrode
Force
kN (Ib)
Welding
Current
(APPW
Amps
Weld
Time
Cycles
0.13 (0.005
to:
0.13 (0.005)4.0 (0.16)4.0 (0.16)O.# (1 00)
3
)
(0.16)0.44 (1 00)
0.25 (0.010) 4.0 (0.1 64.0
3
4.0 (0.16)4.0 (0.16)0.49 (110) 3
0.38 (0.015)
0.53 (0.021)4.0 (0.16)4.0 (0.16)0.49(1 1 O)
3
4.0 (0.16)4.8 (0.19)0.49(1 10)
0.78 (0.031)
3
1.6 (0.063) 4.0 (0.16)4.8 (O.1 9) 0.52(1 20)
3
2.4 (0.093) 4.0(O.16) 4.8(O.1 9) 0.52 (1 20)
3
3.2 (0.125) 4.0 (0.16)4.8 (0.19)0.52(1 20)
3
0.25 (0.010) to
0.25 (0.010) 4.8 (0.19)4.8 (0.19)0.58 (130) 3
0.38 (0.015)4.0 (O.16) 4.8 (0.19)0.58 (130) 3
3
0.53 (0.021)4.0 (O.16) 4.8 (O.19) 0.58 (1 30)
4.0 (0.16)4.8(O.19) 0.58 (1 30)
3
0.78 (0.031)
1.6 (0.063) 4.0 (0.16)4.8(0.19) 0.62 (140) 3
2.4 (0.093) 4.0 (0.16)4.8 (0.19)0.62 (140) 3
3.2 (0.125) 4.0 (0.16)4.8 (0.19)0.67 (150) 3
0.38 (0.0 15) to
0.38(0.015) 4.8 (0.19)4.8 (0.19)11.1 (250) 3
0.53 (0.021)4.8 (0.19) 4.8 (O.19) 11.1 (250) 3
4.8 (0.19) 4.8 (O.1 9) 11.1 (250) 3
0.78 (0.031)
1.6 (0.063) 4.8 (0.19)6.4 (0.25) 1.16 (260) 3
3
2.4 (0.093) 4.8(O.19) 16.0 (0.63)l.lh(260)
3
3.2 (0.125) 4.8 (O.1 9) 16.0 (0.63)1.16(260)
to:
0.53 (0.021)
0.53 (0.021)4.0 (O.16) 4.0 (O.16) 1.65 (370) 4
4
0.78 (0.031)4.0 (0.16)4.0 (0.16)1 .h5 (370)
1.6 (0.063) 4.0(0. 16)4.0 (O.16) 1.65 (370) 4
2.4 (0.093) 4.0 (O.1 6) 16.0 (0.63)1.69 (380) 4
3.2 (0.125) 4.0(O.16) 16.0 (0.63)1.69 (380) 4
to:
0.78 (0.031)
4.8 (0.19)4.8 (O.19) 4.00(900)
4
0.78 (0.031)
4
1.6 (0.063) 4.8 (0.19)4.8 (O.19) 4.00(900)
2.4 (0.093) 4.8(0.19) 4.8 (0.19)4.00(O) 6
3.2 (0.125) 4.8 (0.19)16.0 (0.63)4.36 (980) 6
to:
1.6 (0.063)
6
1.6 (0.063) 6.4 (0.25)6.4 (0.25) 7.65 (1 720)
3.01 (1800)
8
2.4 (0.093) 6.4(0.25) 6.4 (0.25)
3.01 (1800) 10
3.2 (0.125) 6.4 (0.25)6.4 (0.25)
to:
2.4 (0.093)
2.4 (0.093) 7.9 (0.31)7.9 (0.31)3.23 (2300) 12
3.2 (0.125) 7.9 (0.31) 7.9 (0.31)3.23 (2300) 20
to:
3.2 (0.125)
20
3.2 (0.125) 9.5 (0.37) 9.5 (0.37)1.68 (3300)~
7 100
7 400
7 500
7 800
8000
8 100
8 150
8 200
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
+-ILI+
B
&
Minimum
Weld
Spacing
mm (in.)
Nugget
Diameter
mm (in.)
+I
1-D
Shear
Strength
kN (Ib)
6.4(0.25: 9.5 (0.37)2.5 (0.10) 0.13 (30)

6.4(0.25) 7.9 (0.31)
2.5 (0.10) 0.16 (36)
6.4 (0.25)7.9 (0.31)
2.5 (0.10) 0.18(40)
6.4 (0.25)
L2.7 (0.50) 2.5 (O.10)
0.20 (45)
6.4 (0.25)
12.7 (0.50)
2.5 (0.10) 0.22(SO)
6.4 (0.25)9.5 (0.37)
2.5 (0.10) 0.22 (50)
6.4 (0.25) 16.0 (0.63)2.5 (0.10) 0.22(50)
6.4 (0.25)
0.24 (55)
16.0 (0.63)2.5 (O.10)
11 800
1 1 900
12 o00
12 200
12 300
12 300
12 500
6.4 (0.25) 9.5 (0.37)3.0 (0.12)0.60 (135)

6.4 (0.25) 9.5 (0.37)3.0 (0.12) 0.64 (1 45)
6.4 (0.25)7.9 (0.31)3.0 (O.12) 0.67 (I 50)
6.4 (0.25)7.9 (0.31)
3.0 (0.12)0.71 (160)
6.4 (0.25).2.7(0.50) 3.0 (0.12) 0.82 (1 85)
6.4 (0.25)6.0 (0.63)
3.0 (0.12)0.86 (1 YO)
6.4 (0.25).6.0 (0.63)
3.0 (0.12) 0.93 (210)
12 300
12 500
12 600
12 800
13 O00
13 1 0 0
6.4 (0.25) 7.9

6.4 (0.25) 2.7
6.4 (0.25)2.7
6.4 (0.25)
4.3
6.4 (0.25)6.0
6.4 (0.25)6.0
(0.31)3.0 (O.12) 0.80 (180)

(0.50)3.3 (O.13) 1.11 (250)
(0.50)3.3 (0.13)1.25 (280)
(0.56)3.3 (0.13) 1.33 (300)
(0.63)3.3(O.13) 1.56 (350)
(0.63)
3.3 (0.13) 1.38 (310)
7.9
7.9
7.9
7.9
7.9
(0.56)3.0 (0.12) 1.47 (330)

(0.63)
3.0 (0.12) 1.65 (370)
3.0(O.12)
(0.63)
1.76 (400)
(0.69)3.0 (0.12) 1.91 (430)
(0.75)
3.3 (0.13) 2.00 (450)
7 800
8 200
8600
8 800
YO00
(0.31)4.3
(0.31)6.0
(0.31)6.0
(0.31)7.5
(0.31)9.0
15 400
15 200
13 500
14 200
9.5 (0.37)2.2 (0.87)

4.6 (O.18) 3.38 (760)
9.5 (0.37)2.2 (0.87)4.3 (O.17) 3.43 (770)
9.5 (0.37)5.4 (1 .W) 4.6 (0.18)3.74 (840)
9.5 (0.37) 5.4(1 .00) 4.6 (0.18) 4.14 (930)
21 600
20 o00
21 o00
16.0
16.0
16.0
(0.63)8.1 (1.50)6.4 (0.25)0.78 (2400)

(0.63) 1.3 (1.63)6.4 (0.25)1.34 (2550)
(0.63)4.5 (1.75)6.4(0.25) 1.79 (2650)
26 400
25400
19.0
19.0
(0.75)7.6 (1.87)7.9
(0.75)0.8 (2.00) 7.9
(0.31)6.01
(0.31)6.46
(3600)
(3700)
31 O00
!2.2
(0.87)7.2
(0.37) 4.91
(5600)
(2.25)9.5
General Notes:
38
Minimum

AWS Cl .1 M/C1.1:2000
Table 35
Spot Welding Parameters for Nickel-Iron-ChromiumAlloy X'
Weld Time
Cycles
Sheet
Face
Thickness
Diameter
Tip
mm (in.) Material mm (in.) Contour
0.76 (0.030) RWMA 6.4 (0.25)

Class 3
Flat
1.60 (0.063) RWMA 7.9 (0.31)

Class 3
Flat
2.39 (O.OY4) RWMA 9.5 (0.37)

Class 2
Flat
Weld
Force
kN (Ib)
Welding
Current
(Approx.)
Heat Cool Impulses Amps
Forge
Force
kN (Ib)
4.0 (900) 11.1 (2500)
18900
Average
Shear
Strength
(Ib)
Average
Tensile
Strength
kN (Ib) kN
6.13 (1380) 3.88(872)
10(2500)
2
17.8 (4000) 11.1
9
(4400) 33.4 (7500) 19.6
Generdl Note:
1. Nominal chemical cornposition of nickel-iron-chromiumalloy X (UNS NOMX)2),wt.-%: 47.5 Ni, 21.7 Cr, 18.5 Fe, 9.0 Mo, I .5 Co, 0 . 1 C.
Table 36
Seam Welding Parameters for Nickel-Iron-ChromiumAlloy X*
Electrode
Wheel Face
Width'
(Flat Face)
mm (in.)
Sheet
Thickness
mm (in.)
0.76 (0.030)
1.60 (0.063)
2.39 (0.094)
Net Electrode Force

kN (klb)
Weld
4.8 (0.19)
7.9 (0.31)
6.67 (1 SO)
8.90 (2.00)
Weld Time
Forge
Heat
Cycles
Cool
Cycles
None
10
Impulses
1
8
10
2
17.79 (4.00)
20.02 (4.50) 20.0210(4.50) 9.52(0.37)
Welding
Current
(Approx.)
Amps
Welding
Speed
Welds
per m (in.)
None
20 250
15
25
21 500
550 (14)
394 (IO)
Forge
Cycles
33000
315(8)
General Notes:
1. Electrode material: RWMA Class.
2. Nominal chemical composition of nickel-iron-chromium alloyX (UNS NMK)2), wt.-%:47.5 Ni, 21.7 Cr, 18.5 Fe, 9.0 Mo, 15. Co, 0.1 C.
Table 37
Spot Welding Parametersfor Cobalt-Chromium-Nickel Alloy2
Electrode'
Sheet
Thickness
mm (in.)
Diameter
mm (in.)
Tip
Contour
0.76
(0.030)
4.8
Flat
(O. 19)
1.(io
7.9
(0.063) (0.31)
Flat
2.39
12.7
(0.094) (0.50)
Flat
General Noles:

Force
kN (Ib)
Weld Time
Welding
Cool
Heat
Cycles Cycles
Average
Shear
Strength
(Approx.)
Amps
kPa (ksi)
1 Current
Forge
Average
Tensile
Strength
kPa (ksi)
8.915 13 650
5.65
(1.293)
(0.82)
10
0.5
10
2.5
20
0.5
50
200

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
Electrodes
AWS C l .i
M/C1.1:2000
Table 38
Spot Welding Parameters for Various Copper
Alloys
Alloy
Muntz metal
High brass
Cartridge brass
Low brass
Red brass
Manganese red brass
Aluminum bronze
Silicon brass
Silicon bronze
Phosphor bronze
Nickel-aluminum bronze
Nickel-aluminum bronze
(precipitation hardenable)
Weld Time
Cycles
Net Electrode Force

kN (Ib)
4
4
4
6
6
6
4
6
6
6
6
4
1.78 (400)
1.78 (400)
1.78 (400)
1.78 (400)
1.78 (400)
1.78 (400)
1.78 (400)
2.27 (51O)
1.78 (400)
2.27 (5 10)
1.78 (400)
2.27 (510)
Welding Current
Amps
21 o00
21 O00
21 O00
21 o00
21 O00
21 o00
21 o00
21 000
21 o00
21 O00
21 000
21 o00
General Notes:
1. Sheet thickness: 0.91 mm (0.036 in.).
2. Electrode: RWMA Class 1,4.8 mm (0.19 in.)face diameter (flat tip), 30 degrees bevel.
Source: Resistance Welding Theory und Use, American Welding Society, Miami, Florida, 1956.
Table 39
Spot Welding Parameters for TitaniumAlloy 6%AI+%V
Net
mm (in.)
Weld Electrode Sheet

Contacting Welding
Nugget
Time
Force Thickness
Current
Overlap
kN (Ib)
Cycles
Amps
mm (in.)
mm (in.)
5 500
7
0.89 (0.035) 2.67 (600)
10 600
10
1.57 (0.062) 6.67 (1500)
12
11 500
1.78 (0.070) 7.56 (1700)
10.68 (2400) 2.3616(0.093) 12 500
12.7 (0.50)
15.9 (0.63)
15.9 (0.63)
19.0 (0.75)
CrossShear Weld Tension

Penetration Diameter
Strength
Strength
%
k N (Ib)
kN (Ib)
8.4 (0.33)
-
87.3
7.65 (1720) 2.67 (600)

22.22 (5000) 4.45 (1OOo)
28.25 (6350) 8.23 (1850)
9.34 (2100) 37.37 (8400)
General Notes:
1. Electrode: RWMA Class 2, 15.9 mm (0.63 in.) dia. shank, 76 mm (3 in.) tip radius.
2. Squeeze time, cycles: 60.
3. Hold time, cycles: 60.
Source: "Welding and Process Manual-Titanium," Welding Engineer, April 1967.
4.7.6.4 Heat and Cool Times (Seam Welding).If

a slower welding speed is necessary, the cool time should
be increased to maintain the same number of welds per
mm (in,), thus preventing an excessive heat input which
may cause undue distortion of the work. The welds per
mm are related to the welding speed, weld time,and cool
time as shown by the following formula:
U.S. Customary Units:

Welds per in.=
60 x Line Frequency (cycles per second)

(Heat Time + Cool Time) x Welding Speed @./min)
where the heat andcool times are in cycles and the welding speed is in mm per minute (in. per minute).
SI units:
Welds per mm =
4.7.6.5 Off Time. This variable is generally used

when the welding cycle is repetitive.
60 x Line Frequency (cycles per second)

(Heat Time t Cool Time) x Welding Speed (mm/min)
4.7.7 Weld Current. The values shown in the tables

are approximate and are intended to help calculate and
40
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AWS Cl .i
M/C1.1:2000
Table 40
Variation of Current Density and Unit Force Due to
Lack of Electrode Tip Maintenance
~~
Area Tip
400%
Area Tip SmallToo
Proper
Tip Area 56%

Too Large
4
Tip Area 1 2 5 %
Too Large
~~
5
Tip Area 300%
Too Large
W W W
&I B
0.079 cm2
(0.0123 in?)
0.317 cmz
(0.0491 in?)
0.495 cm2
(0.0767 in.3
(0.1105 in.?
1.267 cmz
(0.1964 i n . 3
At Diameter
3.18 mm (0.125 in.)
At Diameter
6.35 (0.250 in.)
At Diameter
7.94 (0.313 in.)
At Diameter
9.52 mm (0.375 in.)
At Diametcr
12.70 mm (0.500 in.)
Unit Force
411 MPa (59 O00 psi)
Unit Force
103 MPa (15 O00 psi)
Unit Force
65 MPd (9 500 psi)
Unit Force
45 MPa ( h 500 psi)
Unit Force
26 MPa (3 710 psi)
0.713 cm2
~~
Current Density
123 690 A/cm2
(798 880
Current Density
31 O00 Ncm2
(200 O00
Result
force and current.
Severe
indentation
and
Ideal
Setup
expulsion from high
current density.
Current Density
19 810 A/cm2
(127 800
Current Density
13 640 A/cm2
(88 O00
Current Density
7 730 A/cm*
(49 900
Result
Only 64% of the
rcquired force
and currcnt.
Result
Only 44%of the
rcquired force
and current.
Result
Only 25% of the
required force
and currcnt.
Weak Spot Weld
Stick Weld
No Weld At All
General Note:
1. Example 2 shows the correct tip size for application requiringa welding force of3250 N (730 Ib) and a welding current of 9800A. Thusa 6.35 mm
(0.250 in.) diameter electrode tip will produce a unit force of 103 MPa (1500 psi) and a current density of 31OU A/cm* (2Ol)OOO
specify the capacity of welding machines. When the

electrode force has been established, the current may be
increased to the point where metal expulsion occurs and
then reduced to just below this point. Optimum strengths,
nugget diameters, and penetration values may be obtained
by this method.
4.7.8 Minimum Contacting Overlap.These values indicate the minimum overlapto obtain satisfactory welds. It
is important to avoid using overlap below these recommended values; otherwise, expulsion
of metal, distortionof
the lapping sheets, or edge welds may occur, andthe weld
may have low strength and contain porosity and cracking.
4.7.7.1WeldScheduleOptions.
Some welding
conditions may benefit from weld schedule
options. These
include preheat, upslope, pulsation, postheat, downslope,
and heat steppers. These options adjust the welding current before, during, and after welding. They may be used
alone or in combination with one another to provide various benefits such as annealing, tempering, increased tip
dressing intervals, longer electrodelife, and reduced power
consumption.
4.7.9 Minimum Spot-Weld Spacing.

The weld spacings
specified are measured from weld center
to weld center.Values less than those indicated create increased shunting currents. This condition requires compensation unless other
measures are usedto compensate for current shuntings.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

4.7.10 Nugget (Fusion Zone) Diameter

or Width.
These values may be used to establish nugget diameter
(spot welds) or width (seam welds).
41
STDOAWS C L * L M / C L - L - E N G L 2000
4.7.11 Minimum Shear and Tensile Strengths.

Tension-shear and cross-tension tests are acceptable methods
of checking of spot welds.
It should be recognized that variations
in individual
weld strengths exist. If weld strength is used to determine an acceptable machine setting, it should be above a
minimum acceptable value.
4.7.12 Spot Welding Various Thickness Combinations and Arrangements.The weldingparameters used
are normally determinedby deciding which of the sheet
thicknesses in a particular combination should determine
or govern the weld schedule. Table 41 shows the
guidelines that should generally be followed in setting up
welding parameters to join various thickness combinations and arrangements of uncoated and coated carbon
and low-alloy steels. In using this table, first refer to the
left column, Metal Combinations and Arrangements,
to identify the applicable metal combination arrangement. Next, select the desired electrode arrangement
from across the top of the table, and locate the boxin that
column that meets the specific combination. The letters
in the boxes refer to the electrode diameters (A and B)
and weld schedule to be used in a particular combination.
These values are determined by finding the welding parameters recommended for the actualX, Y,Z metal sheet
thickness values shown in Tables 1, 2,4, 5 , 6 , 7,9, 10,
and 11. Note that these recommended parameters apply
only to Set-ups with less than the Maximum Thickness
Ratio as shownfor each combination, and a change in
electrode configuration would be required for ratios
greater than these shown. It is also recommended that,
for three sheet combinations, the minimum electrode
spacing be increased by 30 percent above that normally
used for two sheet combinations.
4.8 Weld Discrepancies and Causes.Effective problem
solving ortroubleshooting in resistance welding requires
a knowledge of weld discrepancies and their causes.
Generally, the solution becomes obvious oncethe cause
is determined. The acceptability of a discrepancy depends onthe specific application. The following is a general discussion of weld discrepancies and their causes.
Causes of spot, seam and projection weld discrepancies can be divided into welding equipment related and
process-application related:
(1) Welding-Equipment Related:
(a) Welding machine:
o
Improper machine type
o
Improper kVA rating
o
Inadequate rangeof adjustment of current or
force
o Improper fixture design
o
Excessive friction or inertia in the movable
ram
Electrode tip skidding

Transformer saturation
Broken leads of primaryand
secondary
electrical circuits
Excessive oxide build-up on contact surfaces of secondary circuit
Line voltage variations
Inadequate power supply cooling
Machine mechanical and electrical repeatability
(b) Electrode:
Deformed or worn electrodes thatreduce
the current density at theelectrode-to-workinterface
Poor maintenance or misalignment
Incorrect face shape or geometry
Incorrect alloy
Inadequate water cooling
(c) Welding Control:
Incomplete f u n c t i o m n e or more of the following may be required: pulsation, preheat, forge, quench,
temper, current downslope, or current upslope.
Repeatability
Improper settings
(2) Process Application Related:
(a) Joint Configuration
Poor part fit-up
Poor part design
Inadequate joint overlap
Poor joint accessibility
(b) Surface Condition:
Poor or inconsistent surface finish
Contaminated surfaces
High electrical resistance coatingon surfaces to be welded
(c) Shunting of the welding current:
Through previous welds
Through the part itself
Through fixturing or tooling
(d) Weld Parameters:
Incorrect welding process
Improper welding schedule
Improper projection size or location
Attempting to weld too many widely spaced
projections at once
The following are various problems thatoccur in spot,
seam and projection welding, and their possible causes.
It is assumed that the machine is functioning properly
and that the metalto be welded is resistance weldable.
(I) Expulsion or Porosity at Weld Interface:
o Contaminated surfaces (drawing compoundor
paint)
o Poor part fit-up
o Inadequate joint overlap
o Electrode force too low
0
Weld current too high
42

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
AWS C l .1 M/C1.1:2000
AWS Cl .1 MIC1.1:2000
Table 41
Spot Welding Parameters for Various Thickness Combinations and Arrangements
of Uncoated and Coated-Carbon and Low-Alloy Steels
Electrode Arrangement2.3*
Metal
Thickness
Combinations TipTip
Dia.
Dia.
and
A
Arrangements'
X
X=Y
Max.
B
Thick
Weld
Schedule
Ratio
Y+10%
Y+10%
X/Y=1/4
X+10%
Y
X
X<Y
Y
X
Y
Z
X=Y=Z
x
x
Y
z
x I
Y ' z
z
YCX
Y<Z
x<z
X<Y
Y>Z
x<z
X+15%
Flat
X+15%
X+10%
X/Z=1/2.5
X
Flat
X+15%
X/Z=1/2.5
Flat
Z+15%
X/Z=1/2.5
Z+10%
X/Z=1/2.5
Z
Flat
Z+15%
X/Z=l/2.5
Flat
X+20%X/z
= 112
X<YCZ
X
Y
Z
Y+lO%
X/Z=1/2.5
Z
Flat
Z+15%
X/Z=1/2.5
Flat
Y+20%
X>Y
X
Y
X+1O%
X/Y=1/4
X
Flat
X+10%
?UY=1/4
Flat
X+10% X/Y=1/4
X<Y
X
Y
X+lO% X/Y=1/3
Flat
X+20%
X/Y=1/2.5
Flat
X+20%
X/Y=1/2.5
x=z
z i
x=z
X<Y
Y=Z
X=Y
x<z
X
Y
Z+10%
X/Z=1/2.5
Z
Flat
Z+10%
X/Z=1/2.5
Flat
Z+20%
x/z=112
X
Y
X+15%
X/Z=1/2.5
X
Flat
X+20% x/Z=1/2.5
Flat
Z+20%
x/z=112
x/z= 112
Gcncral Notes:
1. X, Y, and Z are thicknesses.
2. Electrode arrangements 2 and 3 with flat electrodes may not provide satisbctory welds through all three sheets when welding galvanized steel.
3. Where indicated in the weld schedule boxes above, add the indicated
% to weld current andweld force as shown in Tables 1,2,4,5,6,7,9, 10, and 1 I .
4. Tip size and weld schedules are basedon metal thickness as shown in box.
43
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


AWS Cl.lM/C1.1:2000
Weld time too long

Squeeze time too short
Poor electrode follow-up
Improper current pulse shape
Current upslope too fast
(2) Expulsion at Electrode-to-Work Interface:
Contaminated surfaces (drawingcompoundor
paint)
Electrode tip pick-up
Squeeze time too short
Welding current too high
Electrodes not properly contacting the work
Electrode misalignment
Electrode force too low
Incorrect electrode alloy
(3) Undersized Weld or Inadequate Penetration:
Weld time too short
Welding current too low
Electrode force too high or too low
Improper electrode shape
Improperheatbalancecaused
by dissimilar
thickness or metal combination
Projection size too small
Insufficient weld spacing
Shunting of weldingcurrentthroughwelding
fixture
Improper coating and base-metal combination
Projection spacing too large
Excessive line voltage fluctuation
Mushroomed or deformed electrodes
(4)Excessive Surface Indentation or Marking:
Electrode contour too sharp or face too small
Misaligned electrodes
Poor part fit-up
Weld time too long
(5) Cracks in the Weld:
Hold time too short or too long
Forging force applied too late
Improper electrode follow-up
Improper electrode shape
Current decay or downslope not used
Surface contamination
(6) Displaced WeldNuggetwithInadequateWeld
Penetration in One Sheet:
Improperheatbalancecaused
by dissimilar
thicknesses or metals
Improper electrode shape when welding dissimilar thicknesses or dissimilar metals
Misaligned electrodes
Poor part fit-up
Improper combination of electrode materials
(7) Excessive Warpagein Welded Assembly:

Weld time too long
Excessive number of welds
Inadequate electrode cooling
Improper weld sequence
Poor part fit-up
(8) Inadequate or Uneven Set-Down or Upset of Projection Welds:
Excessive welding machine deflection
Improper tooling
Weld time too short
Weld current too low
Improper projection design
Too many projections per electrode
Electrode misalignment
Poor electrode follow-up
(9) Excessive Sheet Separation:
Electrode shape too sharp
Weld force too high or too low
Excessive weld current
Improper part fit-up
Inadequate weld force
(10) Electrode Mushrooming:
Excessivenumberof welds between electrode
dressing or replacement
Weld time too long
Electrodes too small for thickness being welded
Improper electrode material
(1 1) Electrode Sticking:
Weld time too long
Electrodes too small for thickness being welded
Improper electrode material
Surface contamination
4.9 Weld Quality and Mechanical PropertyTests
4.9.1 Introduction. The manufacturer should establish and implementa systematicquality program as specified in ASQC Quality Systems and Management
documents, or other appropriate standards or specifications. Manufacturer standards and specifications should
include standards and specifications, a quantitative definition for weld quality, a procedure for determining if
weld quality standards are being met, and a procedureto
restore weld quality standards when such quality standards are not being met. A form for spot and projection
welding data is provided in Figure 34. A form for seam
welding data is provided in Figure 35.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


S T D = A W S C L * L M / C L = L - E N G L 2000
078'42b5 0513700 734
If the quality programinvolves
production spot weld soundness, particularly for freedom

from cracks or microfissures. The bend test is not precise
enough to calibrate equipment, evaluate machine performance, or to set-up and qualify welding schedules. It is
intended as a supplement to the metallographic, shear, or
peel tests. It can be performed with equipment which is
readily available in most shops and requires only visual
examination of the specimen.
The test consists of bending a test specimen which is
removed from a routine macrosection containing three
welds as shown in Figure 6 . The test specimen is bent
along its length to the angles shown to produce a concentration of the bending stresses successively in each of the
three welds. Before bending, the edges of the specimen
should be rounded andsmoothed to remove burrs.
After bending, the specimen is examined for the presence of cracks or any other surface defects. This test may
be used for seam welds.
testing ofwelded
specimens which are welded coupons instead of actual
welded parts, these specimens should be representative
of the production parts they represent with respect tomaterial, size, shape, thickness combination, surface condition or preparation, contact overlap, and weld spacing
(spot and projection welds) or welds per mm [in.] (seam
welds). A spot or projection welded test specimen may
require only one weld if there is no significant shunt current effect caused by adjacent welds during welding of
the actual parts.
The common weldqualityandmechanicalproperty
tests for resistance spot and seam welds are described in
the following sections.
4.9.2 Destructive Weld Quality Tests

4.9.2.1MetallographicTest.
A metallographic
test is used to determine the weld nugget diameter, penetration, surface indentation, and sheet separation. It is
also used to detect cracks, porosity, nonmetallic inclusions, and metal expulsion.
In this test, weld sections are cut and polished to the
weld centerline, chemically etched" to reveal the microstructure, and then optically examined. For large welds,
the weld nugget diameter and penetration may be measured using dividers or a scale. For small welds, these
values should be determined using a microscope.
4.9.2.4 Chisel Test. This test consists of forcing a

tool into the lap on each side of the weld until the lap
metals separate, as shown in Figure 7.A weld is considered acceptable if it has an average button diameter equal
to or greater than a specified value. The button size is determined in the same manner as in the peel test. This test
differs from a peel test in that actual production parts,selected at random, are evaluated.
4.9.3 NondestructiveWeld-QualityTests.
These
tests fall into twocategories:
(1) tests for after the weld has beenproduced,
(2) tests for measuringthe process response as the
weld is being formed.
4.9.2.2 Peel Test.The peel test is used to determine

the weld button diameter and weld fracture mode of spot
and projection welds.
The test consists of peeling apart a test specimen as
shown in Figure 3. The specimen contact overlap should
be large enough to allow the specimen to be gripped and
peeled apart. To determine the current shunting effect,
several spot welds can be made using the desiredspacing.
The sample is cut transversely before peelingstarts, using
the last weld made as the test sample. Three welds are
recommended for this adaptation as shown in Figure 4.
The size of theweldbuttoncanbemeasured,
as
shown in Figure 5 , to determine if it meets the minimum
requirements.
4.9.23 Bend Test. This test, which was developed
for aluminum and its alloys, is used for a quick check of
11. For suitable etching solutions,see ASTM E 340 and E 407,
Annual Book ofASTM Standards, Vol. 3.01,
American Society
for Testing and Materials, West Conshohocken, Pa., 1990; or

ASM Handbook Volume 8: Mechanical Testing,ASTM International,Materials park,Ohio, 1yg5. Theseetching solutions
can containacids and alcoho]s which arehazardous and can
produce hazardous fumes. Care shall be used (Le., eye protection, rubber gloves, and ventilation hoods) when using these
chemicals. Sce 10.15 to deal with hazardous materials.
4.9.3.1 After-the-Fact Nondestructive Tests.The

tests presently available cannot reliably measure weld
nugget size and penetration. These two factors exert the
strongest influence on weld strength i n resistance spot
and seam weldedjoints.
Nondestructive tests whichmaybeusedon
these
welded joints include: radiographic, fluorescent liquid
penetrant, ultrasonic, and electrical resistance tests. A
magnetic particle test maybe used in place of fluorescent
liquid penetrant on joints made of magnetic metals. Radiographic inspection can detect surface and subsurface
defects such as cracks, porosity, nonmetallic inclusions,
and metal expulsion. Fluorescent liquid penetrant inspection can detect only surface defects. Magnetic particle inspection can detect some defects near the surface i n
addition to surface defects. Ultrasonic and electrical resistance inspections can detect missing welds provided
there is no interfacial diffusion bonding.
- A detailed description of these tests can be found in the latest edition
of the Nondestructive Testins Handbook, by the American Society for Nondestructive Testing, Inc.
45

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
AWS Cl .1 M/C1.1:2000
AWS Cl .1M/C1.1:2000
STEP 2:
BEND SPECIMEN.
OTHER SUITABLE TOOL.
Figure 3-Peel
Test
Process Capability= (Upper Tolerance Limit - Mean)

3 (Standard Deviation)
A chisel test described in 4.9.2.4 maybeused as a

nondestructive shop floortotest check spot weld fusion
on production parts. In this test, a tapered chisel is forced
into the lap of each side of the weld being evaluated until
base
metal
the
begins
deform
to
(acceptable) or an undersized or nonfused weld is revealed (unacceptable). This
evaluation must be carefully interpreted when applied to
zinc-coated steels because, in the absence of weld fusion,
fused zinc may resist relatively highseparation forces.
Process Capability= (Mean - Lower Tolerance Limit)

3 (Standard Deviation)
Choose the one which produces the lower value.
A minimum process capability specification may be
established for each welding application based on the
percentage of unacceptable welds that can be tolerated
without taking any action to reject the welds, The following shows the percentage of welds outside of tolerance
limits as afunction of process capability:
Process
Capability
0.50
O.75
1.o0
1.30
2.00
Percent of Welds
Outside of Tolerance Limits
13.4
2.4
0.27
0.009 6
0.000 o001 8
Operational procedures should be developed and implemented to ensure compliance with the process capability specification at all times. The mean and standard
deviation of weld performance characteristics can be
calculated from measurements of destructively tested
components. Test coupons may be substituted in place of
actual components when it can be demonstrated that
4.9.4 Statistical Weld-Quality Test.The quality of a

sequence of welds can be statistically defined in terms of
process capability. If the weld quality mean and standard
deviation and the specified quality tolerance limits are
known, process capability can be computedas follows:
46

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
4.93.2 Process Response Nondestructive Tests.

Presently available process monitoring systems can measure a wide range of response variables as each weld is
being formed. The most common measurements are current, voltage, resistance, power, energy, electrode force,
workpiece thickness and workpiece thermal expansion.
Thermal expansion exhibits good correlation with weld
strength in many applications. In such applications thermal expansion provides a reliable nondestructive measurement of weld strength. By correlating the measured
thermal expansion response with actual weld strength in
a particular application, expansion limits can be set that
correspond to established weld quality limits.
AWS C1.1M/C1.1:2000
EDGES AS
SHEARED
DIRECTION OF ROLLING
(PREFERRED) \
\x
I
1
l
l
I
i_
!
SPOT
WELD
CENTERED
AS SHOWN
13mm
(0.5 in.)
4
i
i-!
EDGES AS
SHEARED
c D J DIRECTION
OF
ROLLING
(PREFERRED)
I
l
I
I
I
I
J
%%(I(
SPOT WELDS
AS SHOWN
CENTERED
I
,
13mm 4
(0.5 in.)
USE THIRD WELD FOR TEST \
T (Thickness)
mm
(in.)
mm
Up to 0.74
0.76 to 1.47
1.5 to 3.2
Up to (0.029)
(0.030 to 0.058)
(0.059 to 0.125)
16
25
38
L
(in.)
(0.63)
(1.O)
(1 5 )
mm
(in.)
51
76
102
(2)
(3)
(4)
See minimum weld spacing in

Recommended Practice
Figure A P e e l Test Specimens
47

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
STD-AUS C L - L M / C L - L - E N G L 2000 D 07842b5 0533703 443 D

AWS C l .1M/Cl .1:2000
rd-I
rd7
ELLIPTICALLY
SHAPED BUTTON
SPECIMEN PEEL
DIRECTION
(A)
AVERAGE DIAMETER =
SPECIMEN PEEL
DIRECTION
(B)
D+d
2
(C)
NOTE: USE KNIFE EDGE DIAL CALIPERTO MEASURE BUTTON SIZE.
Figure %Measurement of a Weld Button Resultingfrom the Peel Test
measurements of test coupons correlate with measurements of actual components. Nondestructive evaluation
may be substituted in place of destructive testing when
the nondestructive evaluation system can reliably demonstrate that the actual process capability complies with the
process capability specification.
4.9.5 Mechanical Property Tests

4.9.5.1 Spot Weld Tests
4.9.5.1.1 Tension Shear Test.This test consists
of pulling a test specimen in tension to destruction on a
standard tensile testing machine. The test specimen
is made
by overlapping two strips of metal and joining them by a
single weld. The dimensions of the test specimens are
shown in Figure 8.
For specimens 2.6 mm (0.10 in.) thick and over, it is
suggested that pads be attached to specimens to avoid
bending in the grips of the testing machine.
The ultimate strength of the specimen and the mode
of failure, such as shearingof the weld metal, or tearing
of the base metal, and typeof fracture (ductile or brittle)
is determined.
It may also be desirable tomeasureandreportthe
bend angle between the weld interface and the tensile
axis at fracture, as shown in Figure 9. Note that this angle
may also be referred to as the angle of twist. The bend
angle value is an important parameter which not only
characterizes thestress conditions andthe plastic deformation of the weld interface and adjacent base metal,
but also
can be correlated with the fracture mode of the welded
48
joint. Normally, a small bend angle is associated with

weld interface shear failure. A large bend angle is associated with the fracture of the base metal adjacent to the
weld.
4.9.5.1.2 Tension Tests.The purpose of the tension test is to providea method to determine thespot weld
strength under tensile loading. The ultimate strength of
the weld, the diameter of the weld button and the method
of fracture can also be determined.
The ultimate tensile strength determined by this test is
a better measure of sensitivity to embrittlement due to
stress concentration at the spot weld than is the tensile
shear strength obtained with the tensile shear test. The
ratio of the tensile strength to the tension shear strength
is frequently referred toas the ductility of the weld.
' b o types of tension tests, the cross-joint tension test
and the U-specimen tension test, are used as specified by
the design requirementsof the part being welded and the
testing fixtures available.
(1) Cross-Joint Tension Test. This test is designed to
stress the weld in a direction normal to the surface of the
material. Dimensions of the welded cross-joint tension
specimens are shownin Figure 10. Special holding fixtures
are constructed to apply normal tension to the specimens.
The fixture for holding the 50 x 150 mm (2 x 6 in.)
cross specimen of Figure 10A is shown in Figure 11.
The fixture is intended for sheet thicknesses up to
4.8 mm (0.19 in.). Various methods of holding the fixture in the testing machinemay be used, such as pin connections, wedge grips, or threaded-end testing fixtures.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

S T D - A W S C L = L f l / C Z = L - E N G L 2000
0 7 8 4 2 b 5 051370'4 38T
AWS Cl.lMIC1.1:2000
PREPARATION OF SPECIMEN
SAW CUT. FILE SMOOTH AND
POLISH. (FOR MACROETCH
SPECIMEN SEE PAR. 504.5)
SECOND CUT. SAW AND
REMOVE BURRS.
1.6 TO 2.4 mm (0.06 TO 0.09 in.) UNIFORM WIDTH AFTER POLISHING.

POLISHED SURFACE
WELD
(z
3. SPECIMENREADY FOR
BENDING WITH POLISHED
SURFACE ON OUTSIDE
OF BEND.
ROUGH SURFACE
4. SPECIMENASTESTED.
5. FOR SEAM WELDS FOLLOW

SAMEPROCEDURE.LENGTH
OF SPECIMEN MAY BE
INCREASED TO ABOUT
150 mm (6.0 in.).
MAX INSIDE
BEND RADIUS
T (Thickness)
mm
(in.)
Up to 0.74
0.76 to 1.47
1.5 to 3.2
up to (0.029)
(0.030 to 0.058)
(0.059to 0.1 25)
mm
16
i:
L
mm
(in.)
51
(0.63)
:i:$
(in.)
spacing weld(2)
minimum See
li:
Recommended
Practice
Figure &Bend Test Specimen
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

49
in
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
Figure 7-spot Weld Chisel Test
SPOT WELD C E N T E R D ~
AS SHOWN
T (Thickness of Thinner Sheet)

mm
Up to 0.76
0.79 to 1.27
1.3 to2.5
2.6 to 3.3
3.3 to 4.8
4.8 and over
(in.)
up to (0.030)
(0.031 to 0.050)
to 0.100)
(0.101 toO.130)
(0.131 to 0.190)
(0.191) and over
W (Specimen Width)
mm
L (Recommended Length
(in.)
(in.)
16
(0.63)
19
(0.75)
25 (0.051 (1.O)
32
(5)(1.25)
313
(5)(15 )
51
(2.0)
102
127
127
152
Figure &Tension-Shear Test Specimen

50

S T D - A W S C L - L M / C L = 1 - E N G L 200.0
07842b5 O51370b 152

AWS Cl.lM/C1.1:2000
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
INTERFACE
FRACTURE
PULL-OUT
FRACTURE
Figure %Twisting Angle y at Fracture in Tension Shear Test
4.9.5.13 Pull Test. A pull test determines

the resistance of the welded joint to the opening mode of
fracture. Tensile load is applied at
a 90 angleto the joint
interface as shown in Figure 15. I t should be noted that
this test may also be referredto as a90peel test.
For this test, a conventional tensile testing machine is
used to provide the tension force.The grips serve as reinforcement plates to minimize the elongationof the specimen in regions outside the weld. The distances between
the sheet surfaces of the welded joint, positioned in the
horizontal plane (at90 to the tension axis), and the adjacent endsurfaces of the grips should be sufficientlysmall
to minimize the elongation, but large enough so that the
grip ends do not interfere with the deformation of the
welded joint during the test. In preparation of a 90 pull
arm, the weld nugget should not be disturbed. This can
be achieved by clamping the nugget of the spot weld
specimen in a vise so that the edge of the vise is aligned
with the pull edge of the nugget, and
bending onesheet
of the specimen to 90 with respect to the other sheet.
The distance from the load axis of the pull arm to the
nuggets pull edge should be equal to theminimum bend
radius of the metal to avoid cracking. For a given material and temper, the selected or experimentally determined minimum bend radius should be the same for a
data comparison. For ductile metals, the minimum bend
radius of curvature should not exceed the thickness of
one of the welded sheets.
A self-aligning feature is desirable and precautions

should betaken to prevent thespecimen from slipping in
the holding fixture.
The fixture for holding the 76 x 204 mm (3 x 8 in.)
cross-joint specimen of Figure 10B is shown in Figure
12. This fixture is intended for thicknesses over 4.8 mm
(0.19 in.) thick. Figure 12A shows a specimen in the
lower portion of the testing fixture.
Tension at right angles to the plane of the joint is produced by applying compression to the fixture holding the
specimen. The U-shaped yokes with the hold down
screws are used to partially restrain the specimen from
bending by introducing semifixedends to the beam represented by each separate plate. Figure
12 shows the specimen
completely assembled in the fixture with the compression
head of the testing machine i n contact with the fixture
and ready for applying load to the specimen.
(2) U-SpecimenTensionTest. A tensiontest may
also be made on U-shaped specimens as shown in Figure
13. The U-sections are welded as shown and pulled to
destruction in a standard tensile testing machine. Supporting or spacer blocks must be provided, as shown in
Figure 14, for confining the sample so that loading takes
place at the weld. This test is limited to those thicknesses
and metals that can readily be bent to the radius indicated. For magnesium, high-strength aluminum alloys,
and other alloys that cannot tolerate the indicated radius
of bend, the radius must be increased to a suitable value.
51

S T D - A W S C ~ - L M / C L - I J - E N G L 2000
0 7 8 9 2 b 5 0513707 O77 9
AWSCl.lM/C1.1:2000
101.6 0.8 mm
(4.00 0.03 in.)
'"
'4 I- (:5;:)7
(O. 19 in.)
b*,
P-
SPOT WELD CENTERED

AS SHOWN
51 mm (2.0 in.)
204 mm (8.0 in.)
38 mm
T = THICKNESS
4.8 mm (0.19 in.)
AND OVER
(1.5 in.)
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
T = THICKNESS
UP TO 4.8 mm
(A)
'
SPOT
WELD
CENTERED
AS SHOWN
(3.0in.)
Figure lO-Cross-Tension Test Specimens
52

STD-AWS C L = L M / C L - L - E N G L ZOO0
0 7 8 4 2 b 5 0513708 T 2 5
AWS Cl .1 M/Cl.l:2OOo
19 m m
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
25 m m
(1.O in.)
25 m m
(1 .O in.)
(0.5 in.)
Figure 11-Fixture for Cross-Tension Test

(for Thicknesses up to 4.8 m m [0.19 in.])
53

STD-AWS C l * l M / C l - L - E N G L 2000 m 078'42b5 0513709 9 b l m
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
76 mm (3.0 in.)
Figure 12-Fixture for Cross-Tension Test (for Thicknesses 4.8 mm [0.19 in.] and Over)
4.9.5.1.4 Torsion Shear Test. A torsion-shear

test for evaluating spot welds may be used where a measure of strength and ductility is required. A typical Set-up
for this test is shown in Figure 16. Torsional shear is applied on the weld of a square test specimen by placing
the specimen between two recessed plates. The upper
plate is held rigid by a hinge while the lower is fastened
to a rotating disk. After the specimen is placed in the
square recess of the lower plate, the upper plate is closed
over it and locked in position. Torque is applied by
means of a rack and pinion attached to the disk. It is important that the upper and lower sheets of the specimen
be engaged separately by the two plates and the weld be
centrally located with respectto the axis of rotation.
Three values are determined forthe weld area:
(1) Ultimate torque required to twist the weld to destruction (computed by multiplying the maximum loadin
newtons [pounds-force]) by the moment arm in m (in.).
(2) Angle of twist at ultimate torque (measuredby the
angle of rotation at maximum load).
(3) Weld diameter (measured after the test specimen
is broken).
The weld strength can be determined using the ultimate torque and weld diameter, and the ductility by the
angle of twist.
It is possible to use the test values obtained (ultimate

torque, angle of twist, and weld diameter) to indicate
quality. This may be done by using the standard torsional
formula:
C
s, = M
I
where
I = moment of inertia (m4 [in.")
S , = torsional shear stress (Pa [psi])
M = torque (N-m [in. pound-force])

c = distance from external fiber to central axis (m
[inel)
The torsional shear stress values obtained for the external fibers, termed the modulus of rupture, are directly
proportional to the tension shear stress. The modulus of
rupture, as determined by actual tests on low-carbon
54


AWS Cl.lM/C1.1:2000
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
EDGES AS
SHEARED
I\
- *"
(D) DIAMETER DRILL
(Thickness)
R*
~~
mm (in.) mm (in.) mm
0.100)
25 to Up2.54to Up
mm
mm (in.)
(1)
25
(in.) mm
(in.)(in.) mm
13 4.0(0.5)
(1) 25
(0.33)
8.3
(1)
)3(1) 25 (2) 51 (2)

2.56and
51
over)
and
(0.101
over
(0.16)
(2) (0.25)
6.4
*For magnesium, high-strength aluminum alloys and other alloys that cannot tolerate these radii, the radius must be increased
to a
of the capabilityof the particular material.It isdesirable to form these specimens without the necessity
of
suitable value within the limits
heating as this will modify the results.
Figure 13-U-Test Specimen
55

AWS Cl .I M/C1.1:2OOO
'D" DIAMETER
THRU \
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
)-" E
+-4
32 mm
(1-26in.)
TWO REQUIRED
(in.)
mm
Up to 2.54
T (Thickness)
(in.)
mm
Up to (0.100)
2.56and over (0.101over)

and
(in.)
mm
25
(1)
25
51
(2)
51
(2)
25
(in.)
mm
(1)
(in.)
mm
mm
13
(0.5)
8.7
(0.34)
25
(1)
R*
14.3
(0.56)
51
(2)
(in.) (in.)
mm
(1)
(in.)
mm
4.0 (0.16)
57
(2.25)
6.4 (0.25)
82
(3.25)
**For magnesium, high-strength aluminum alloys and other alloys that cannot tolerate these radii, the radius must be increased
to a
of the capabilityof the particular material.It isdesirable to form these specimens without the necessity
of
suitable value within the limits
heating as this will modify the results.
Figure 14-U-Tension Test Jig
1
Figure 15-Pull Test
(90-Degree Peel Test)

56


S T D = A W S C L - L M / C L - L - E N G L 2000
078'42b5 0533732 q5b
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
AWSCl.lM/C1.1:2000
SPECIMEN
LOCKING HANDLE
(HOLDS GATE IN PLACE)
SPOT WELD
CENTER
AS SHOWN
(1.97 in.)
50 m m __._c
(1.97 in.)
Figure l4-Test Specimen and Typical Equipment

for Torsion-Shear Test
57

STDDAWS CII-~M/CL.L-ENGL 2000

AWS Cl .1 M/Cl.1:2000
3.2 m m (0.125 in.) thickness, it is necessary to have

pendulum bobs of different weights.
steels, was found to be approximately twice the tension

shear stress.
An additional benefit of torsional testingis that it also
allows the determination of tension shear strength by
using the following equations:
s, = 2SL
In this type of test, the specimen is held by serrated

wedge grips in the special pendulum bob and cross-head
attachments. When the machine is operated, both the
crosshead and bob, which are connected by the welded
specimen, fall until the cross-head is caught by adjustable anvils at the bottom of the pendulum swing. The
pendulum bob is free to continue its swing, and will do
so, provided sufficient energy is available to fracture the
specimen. The residual swing of the pendulum indicates
the impact load, in newton-meters (foot-pounds-force),
necessary to break the weld. Care should be taken to
properly tighten the wedge grips so that no errors are introduced by slippage of the specimen during the test. If
grip slippage is a serious problem, pin connections may
be used to supplement the grips, The striking surface of
the cross-head and the impact-receiving surface of the
anvil should be perpendicular to the longitudinal axis of
the specimen to preclude errors caused by twist load.
Tests may be made at various velocities which should be
not less than 3 m/s (10 ft/s) or more than 6m/s (20 fus).
Velocity should always be stated as a maximum tangential velocity of the cross-head striking surface. The impact value should be taken as the energy absorbed in
breaking the weld, andis equal to the difference between
the energy in the entire striking unit, which may, for example, consist of pendulum, pendulum bob, specimen
and cross-head, at the instant of impact with the anvil and
the energy remaining after breaking the weld. For maximum energy, the kinetic energy imparted to the tooling
should be taken into account.Similar to the requirements
for tension shear test,
it is desirable to determine and report
the bending angleat fracture as measured after the test.
When making shear-impact tests, some of the energy
is absorbed in plastic deformation of the sheets. In order
to control the extentof this deformation, the distance between grips should be not less than 125 mm (4.9 in.) nor
more than 129 mm (5.1 in.).
Since large changes in spot weldimpact strength
occur with relatively small changes in sheet thickness
and weld size, the coverage obtained by any one pendulum bob assembly is limited.
( m . 1)
where
SL = tension shear stress
Mc - 2L
"-
I
A
where
L = straight shear load
A = cross-sectional area
Substituting ultimate torque (T) for torque M, and L
for straight shear load,
TD
-2
=-
2L
nD2
nD4
32
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
"
L = -2T
D
or
shear load [N (pound-force)] =
2{ ulitmate torque IN-m (in. pound-force)u
weld diameter [m (in.)]
( W 3)
The above formula gives the approximate relation between shear strength and torque required to shear the
weld, thereby permitting evaluation of the shear strength
by torsional testing, or by calculating the ultimate torque
from the shear load.
Whentestedandcomputed
as indicatedabove,the
strength values for single spot welds may be determined.
4.9.5.1.5 Impact Test.The impact test differentiates between degrees of weld resistance to fracture
under impact load. Five types of impact tests are described here:
4.9.5.1.5.2 Cross-Joint Drop-Impact Test.

Since the range of the ordinary pendulum-type impact
testing machine willnot permit tension shear impact tests
to be made on spot welded sheets of thicknesses greater
than 3.2 mm (0.125 in.), a different procedure must be
used to apply impact loads to welds in the heavier gage
metals. The most critical direction in which an impact
load may be applied to spot welds in heavy plate is in a
direction normal to the plate surfaces. This may be accomplished using a test specimen similar to that used for
4.9.5.1.5.1
Tension
Shear-Impact
Test
(limited to thicknesses up to 3.2 mm (0.125 in.). A satisfactory shear-impact test for spot welds may be obtained
by using the 51 x 152 mm (2 x 6 in.) tension shear specimen (see Figure 8), and a modified 50 to 100 N (1 1 to
22 pound-force) pendulum-type impact testing machine.
To satisfactorily test welds in sheets up to and including
58

AWS C l .1 M/C1.1:2000
amount of friction may be controlled by means of springloaded machine screws. An arm on the aluminum push
rod provides a convenient place for an indicator dial
gauge to be used to measure the maximum deflection of
the springs (see Figure 18). A calibration curve for residual energy may be obtained by dropping the weight from
various heights corresponding to various potential energies of the moving system.
The results obtained with the cross-joint drop-impact
test are subject to two types of error. Both of these are
concerned with the behavior of thinner plates and the
softer types of steel. One source of error is the inability
to restrain the lower plate against bending.In this case, if
the lower plate is thin and soft, too much bending will be
produced, and either the specimen will not break or a
large portion of the impact energy will be absorbed in
bending of the plate. Although the ability of a weld to
force the plate to bend may be a good indication of weld
quality, the resultant impact energy absorbed by bending
will not be a good measure of the weld strength. On the
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
the cross-joint tension test with added reinforcement as

shown in Figure 17.
The principal components of a drop weightimpact
machine are a vertically guided, free-falling weight, a
rigidly supported anvil, and a pair of calibrated springs
placed below the specimen or other type of force transducer arrangement to measure the remaining energy of
the weight after the weld fractures (see Figure 18). The
lower portion of the weight is designed as a fork to assure that the impact of the weight will be applied equally
to both sides of the lower plate of the specimen. The
width of the opening between the two prongsof the fork
of the weight is made 79 mm (3.12 in.), 3 mm (0.12 in.)
greater than the specimen plate width of 76 mm (3.0 in.)
to permit the small clearancebetween the inside surfaces
of the fork and the clamped upper plate.
When calibrated springs are used to measure the remaining energy after the test, the maximum deflection of
the springs may be indicated by an aluminum push rod
moving between a pair of bronze friction plates. The
7
204
BRACING PLATESAME THICKNESS AS

BOTTOM PLATE
DIMENSIONS SHOWN ARE IN m m (in.)
Figure 17-Drop-Impact Test Specimen

59

STDDAWS C L * L M / C L * L - E N G L 2000
AWSCl.lM/C1.1:2000
U-shaped sections back to back by a single spot weld as

shown in Figure 13. The specimen is dynamically loaded
in a pendulum type impact testing machine withat least a
300 Nm (220 foot pounds-force) capacity. The test fixture is so designed that theforce applied in fracturing the
specimen is essentially in shear as shown in Figure 19.
The operationof this test is similar to that described for
the tension shear-impact test. The energy (Nm [foot
pounds-force]) consumed in fracturing the specimen and
the mode offailure are recorded.
DIRECTION OF LOADING
4.95.1.5.4 U-Specimen
Tension-Impact
Loading Test. This test also utilizes the U-shaped test
specimen shown in Figure 13. In this case, the test fixture
is so designed that the forces applied in fracturing the
specimen arein tension as shown in Figure 20. In all other
respects, this test is the same as the U-specimen shearimpact test.
4.9.5.1.5.5 Instrumented Impact Test. The
instrumented impact test electronically records the load
versus time and the impact energy versus timetraces to
follow thedynamic fracture process of the specimen.The
instrument consists of
(1) Load transducer placed on the pendulum bob to
sense the specimen loading,
(2) Electronic signal conditioning circuit, and
(3) Graphic recording equipment for plotting the
transducer output versus time.
For certain alloys and specimen configurations, load
signal oscillation may occur and become excessive. The
accuracy of load values is assured if sufficient damping
is achieved. For an accurate determination of the peak
load, it should be required that the time to the peak load
is at least three times the periodof the oscillation.
Figure 18-Drop-Impact Test Machine
other hand, severe plastic deformation of the plate material in the vicinity of the weld is a much better indicator
of weld quality. Therefore, plate bending at some distance from the weld should be avoided. The second
source of error in impact testing is bending of the upper
plate and slippage of the specimenin the clamps. Both of
these cause absorption of additional energy, and a true
measure of weld toughnessis not obtained.
In order to avoid the possibilities for the errors mentioned above, two methods may be used to minimize
bending and grip slippage in the upper plate. One is to
provide serrated jaws for clamping to prevent slippage.
The other is to place another plate directly over the upper
plate and to attach theseplates at their ends by additional
spot welds, as illustrated in Figure 17. In this case, the
extra plate is in compression during the test, preventing
excessive plate bending due to grip slippage. In the testing of a thin plate welded to a thicker one, the heavier
plate is arranged to be struck by the falling weight. The
precautions as mentioned above should be used withthe
upper plate to ensure a satisfactory impact test. If both
plates are thin and soft, it may be necessary to reinforce
the lower plate in a manner similar to that used to stiffen
the upper plate.
4.9.5.1.6 Fatigue Test. The fatigue test is performed using the shear test specimen (see Figure 8). The
specimen is mounted in the fatigue tester using utmost
care to align the weld with theforce center. Fatigue tests
of spot and projection welds are often conducted with a
ratio of minimum stress to maximum stress of 0.1. Maximum tensile load should never occur at less than 25 percent of the machinesoperating range. There are different
types of fatigue testing machines, such as the (1) mechanical (eccentric crank, powerscrews, rotating masses)
type, (2) hydraulic or electrohydraulic type, and (3) electromechanical or magnetically driven type. A typical fatigue test set-upis shown in Figure 21.
The selectedfatigue testing machine should permit
cycling between the intended stress or strain limits. For
constant-amplitude low-cycle (less than lo5 cycles) fatigue, the machine control stability should be such that
the respectivestress or strain limit is repeatable from cycle
to cycle to within0.5 percent of the average control limit
and repeatable over the test duration to within 2 percent
4.9.5.153 U-Specimen Shear-Impact Test.

This test utilizes the specimen made by joining two
60
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


S T D - A W S CL=LM/CI,.I,-ENGL
zoou m
1 1 7 ~ w b 50 5 1 , 3 7 1 ~UTI,
AWS C l .1M/C1.1:2000
4l
L.,
] *.
- "-
"
"
"
ATTACH TO
PENDULUM BOB
"
@I-
ATTACH TO
CROSSHEAD
i
1
Figure 1P-Test Fixture for Shear-Impact Loading Test
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
c
AlTACH TO
PENDULUM
ATTACH TO
BOB
Figure 20"Test Fixture for Tension-Impact Loading Test
of the average control limit. Either strain rate or frequency of cycling should be constant for the duration of
each test. Although constant strain rate testing is often
preferred, and is experimentally more tractable than constant frequency testing, the latter may be of greater practical significance to the fatigue analysis of resistance
welds for certain applications. In high-cycle fatigue tests,
the test loads should be monitored continuously in the
early stage of the test and periodically maintained.
The machine should have minimalbacklash in the
loading train. The varying stress, as determined by a suitable dynamic verification, should be maintained at all
times to within2 percent of the machine operating range.

Below a certain frequency (e.g., 170 Hz depending on
the metal), the fatigue effects due to frequency are negligible. Above this frequency, the effect of frequency on
the fatigue strength may be significant and should be reported particularly if the materials are strain rate sensitive. As in the tension shear test, the rotation (twisting)
angle (Figure 9) of the weld interface should be recorded
( e g , by photographs) to characterize the stress conditions and plastic deformation, and to correlate it with the
fracture mode of the welded joint and adjacent base
metal.
61


AWS Cl.lM/C1.1:2000
R = Minimum axial stress

Maximum axial stress
OSCILLATING LOAD
OBTAINED
THROUGH
AN
For zero minimum axial stress, R = O.

(2) Rotation angle immediately before or at failure.
4.9.5.2 Seam Weld Tests

4.9.5.2.1 Tension Shear Test. To determine the
shear strength of a seam weld, the tension shear test
specimen (see Figure 8) previously described should
contain a seam weld, in place of the spot weld, perpendicular to the axis of the tensile load.
4.9.5.2.2 Pillow Test or Pressure Test. Seam
welding is an extension of spot welding wherethe spots
provide a continuousweld. This type of weld is usually
employed where leak-tightnessis required. A test simulating the service conditions of the welded joint furnishes
the best measureof the weld quality.
For this purpose, twoflat plates of the same thickness,
as used in production, are prepared and seam welded
around the outside edge, sealing the space between the
plates. A pipe connection is then welded to a hole drilled
in the top plateas shown in Figure 22. After the assembly
is attached to a hydraulic system, pressure is applied.
r-
r r--
I (I
152
(6.0)
152 (6.0)
I
1
"7
Figure 21-Fatigue Testing Machine

L"
To evaluatethe fatigue performance of the welded

joint, the following information should be reported:
(1) Totalnumberof
cycles tofailure (Nf), which
should be accompanied by the following information:
(a) The failure definition used in the determination of Nf (e.g., crack size or complete separation).
(b) Location of crack initiation.
(c) Frequency of cycling and shape of load time
curve.
(d) Mode of control (e.g., load, stress, continuous
strain control, or strain limit control).
Axial
(e)
stress ratio R, where:
DRILL HOLE IN ONE PLATE AND

ARC WELD OR SILVER BRAZE
STANDARD-PIPE NIPPLE
CENTRALLY OVER HOLE.
DIMENSIONS SHOWN ARE IN mm (in.)
Figure 22-Pillow
Test for Seam

Welds
62
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


AWSCl.lM/C1.1:2000
The pillow can be so distorted as to cause excessive

loading in some spots with little loading in other spots.
Consequently, it may be necessary to restrict deformation
of the pillow by inserting a plate above and below it
while testing, particularly in soft or thin material.
The measure of a good weld is no leakage at a prescribed pressure or when failure occurs in the base metal.
The pillow specimens can be tested under cyclic pressures
to determine the fatigue strengthof the welded joint.
tion in current density which reduces the concentrated

heat generation from resistance heating. This prevents
the projection contact area temperature from increasing
high enough to promote satisfactory welding. Bulk resistivity, to a lesser degree, also plays a role in projection
welding. Increased bulk resistivity has the effect of reducing the effectiveness of the projection as a current
concentrator. With increasing bulk resistivity, there is a
tendency for delocalized heating and general, rather than
local, collapse of the projection. As a result, high resistivity materials are more difficult to projection weld.
Materials that are ideal for projection welding include
mild steels and low-alloy, nickel-based materials. These
materials have adequate strength at high temperatures,
proper resistivity, and readily dissociatable surface oxides to promote welding. Stainless steels and higher alloy
content nickel-based materials are more difficult to weld
because of their high temperature strength and adherent
surface oxides. Copper and copper alloys can also be
projection welded. Projection welding is preferred over
spot welding because of the difficulties these highly conductive materials cause in spot welding. Aluminum and
aluminum-based alloys are quite difficult to projection
weld because of the tenacious aluminum oxide coating
associated with aluminum and the low strength of most
aluminum alloys at high temperatures (resulting in premature projection collapse). Titaniumalloys are also difficult to weld using projections because of their high
resistivity and low strength at elevated temperatures
which promotes premature projection collapse.
5. Projection Welding
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
5.1 Introduction. Projection welding (PW) is a resistance welding process that produces a weld by the heat
obtained from the resistance to the flow of the welding
current. The resulting welds are localized at predetermined points by projections, embossments, or intersections. The point of contact is with a local geometric
extension (projection) of one (or both) of the parts.These
projections are used to concentrate heat generation at the
point of contact. Projection welding can typically be
done using lower currents, lower forces, and shorter
welding times than a similar spot welding application.
Projection welding applications are generally classified as either embossed or solid projection welding.
These are shown in Figures 23 and 24.
Embossed projection welding is generally a sheet-tosheet joining process in which a projection is stamped or
pressed into one or more of the sheets to be joined. During welding, heatingis initially concentrated at the contact point and in the walls of the projection. Early in the
process, the projection almost completely collapses back
into the original sheet. Weld development proceeds in a
manner similar to spot welding whereby a fused weld
nugget is formed at the point of current concentration.
Completed embossed projection welds are often indistinguishable from conventional resistance spot welds,
In solid projection welding, the projectionmay be machined or formed on one of the two components being
joined. During resistance heating, the contact point and
the projection itself experience a significant increase in
temperature. The projection then collapses by both penetrating the opposing material and by upsetting (or extruding to the periphery). This weld typically resembles a
solid state diffusion weld, with a minimal fused zone,
rather than a spot weld.
Since theprojectionstypically
collapse duringthe
projection welding process, the strength of the material
being welded, particularly at high temperatures, affects
the projection weldability. Materials that maintain their
strengths up to relatively high temperatures permit substantial heating to occur before the projection collapses.
Premature collapse of the projection results in a reduc-
5.2 Embossed Projection Welding

5.2.1 Projection Designand Welding Parameters
5.2.1.1 Heavy-GaugeSheet. Projectionwelding
heavy-gauge steels is nominally an embossed projection
welding process. However, the process has many of the
characteristics of solid projection welding becauseof the
higher apparent material strengths associated with the
larger masses. Projection designs, in addition to defining
the geometry of the projection, normally provide an annular relief for the projection material which is forged or
extruded to the side during welding similar to that of
solid projection designs. Projection and die geometries
for steels ranging from 3.12-6.22 mm (0.123-0.245 in.)
are presented in Table 42. Process requirements for forming these welds are presentedin Table 43. To prevent preflashing of the projection on initiation of the welding
current, upslopes are recommended. In addition, since weld
porosity is often a concern, forge forces are also recommended. All welding schedules shown are single-pulse
welding schedules. As with spot welding heavy section
steels, however, excessive electrode or die wear may be a
concern. In such applications, pulsation welding schedules might be recommended to alleviate tooling wear.
63

STD-AWS C L - L M / C b * b - E N G L 2000 M 078ri2b5 0533737 800 H

AWS Cl .1M/C1.1:2OOO
INITIAL CONFIGURATION
AFTER WELDING
Figure 23-mpical Stack-up Configuration

of Sheet
for Embossed Projection Welding
INITIAL CONFIGURATION
\\''
AFTER WELDING
Figure 24"Qpical Configuration for Solid Projection Welding
64
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

S T D - A W S CL.LM/CL*L-ENGL
07892b5 0533720 5 2 2
2000
AWS C l .1M/C1.1:2000
?99
see
I
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66

AWS Cl.lMIC1.1:2000
53.1.3 AnnularProjectionWelding.
Specific
projection design and processconditions for annular projection welding are not uniformly established. There is
general consensus on the use of90 degree included angle
triangular cross-section projections scaled to the thickness of the opposing sheet. An annular relief groovemay
also be required to provide an outlet for material in the
projection that is forged or extruded during welding.
Typical practices use 4.4-8.8 kN (1000-2000 Ib-f) force
per linear meter (in.) of projection. Weld times for diameters of 6.4-25 mm (0.25-1.00 in.) usually range from
one to ten cycles.
Annular projections are normally offset from the
outer
periphery of the part. Projection designs which extend to
the outside of the part have the potential of unstable projection collapse. This can result in formation of notches
or bulges at the joint. This is illustrated in Figure 26.
Whenlargerdiameterannularprojection
welds are
made, there may be problems encountered in achieving
proper heat balance around the entire periphery of the
projection. Direct current machines or optimized transformer arrangementsmay be required to overcome such
problems.
5.2.1.2
Intermediate-Gauge
Sheet.
Projection
welding intermediate gauges of steel, 0.5-3.30 m m
(0.020-0.130 in.), is well established using single-point
projections with single-impulse weldingschedules. Projection stamping die designs are given in Tables 42 and
44 through 46. Process requirementsare given in Tables
47 through 49. These gauges typically require lower forces
and shorter welding times for projection welding compared to spot welding.
5.2.13 Thin-GaugeSheet. Projectionwelding
thin-gauge steel sheet, less than 0.51 mm (0.020 in.), differs significantly from projection welding intermediate
sheet because of the mechanical instability of the single
point projections. Annular projections are typically recommended for these gauges to provide added projection
strength to avoid premature projection collapse. Annular
projection geometry and recommended welding process
parameters are presented in Table 50.
5.2.1.4 Dissimilar Metal Thicknesses. Projection
welding is ideally suited forjoining materials of dissimilar
thicknesses. The projection is placed on the thicker sheet
(for heat balance), using the recommended projection design for that sheet (see Table 5 l).The projection has the
effect of concentrating the heat at the contact surface.
5.4 Multiple Projection Welding.Multiple projections

require additional care in electrode design to assure that
the electrode contacts the workpiece and provides uniform current distribution to all projections. It is normally
recommended that the electrode contact face be at least
twice the diameter of the projection pattern. Welding
conditions are normally proportionally the same as those
shown in the tables for single projection welds. For multiple projections,multiply the electrode force and welding
current for one projection by the number of projections
of the workpiece. The welding time, however, remains
the same as for single projection welding.
5.3 Solid Projection Welding

53.1 Projection Design and Welding Parameters
53.1.1 Nut Welding. Assorted nuts and fasteners
can be successfully mounted to intermediate and heavygauge sheets using projection welding. The process can
also be used with thinner gauge sheets, but more care is
required in preventing distortion to the thinner sheet due
to projection penetration. Three projections are normally
used in nut welding to assure uniformity in projection
contact with the opposing surface when the electrode
force is applied. Such projections are normally scaled according to the sheet being joined as indicated in Table 52.
5.5 Weld Quality and Mechanical Property Tests.

Tests for resistance spot welds can be applied for projection welds. However, some modifications may be required due to workpiece geometry or dissimilarity in
metal thicknesses joined.
53.1.2 Cross-WireWelding. Cross-wire welds

are normally characterized as solid state diffusion welds
rather than fusion welds, although some fusion may occur. Process conditions for cross-wire welding are shown
in Table 53 for a range of wire thicknesses. Welding conditions are usually specified in terms of the requirements
for achieving a certain level of set-down (or collapse) for
the wires. Set-down is defined in Figure 25. As the percentage of set-down increases(up to 50 percent), thejoint
strength increases as more bond area is established. The
process conditions defined are for mild steels. Higher
strength materials,such as stainless and nickel-based alloys,
will require higher forces and longer welding times to
promote the wire collapse and bonding.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

6. Flash Welding
6.1 Introduction. Flash welding (FW) is a resistance
welding process that produces a weld at the faying surfaces of a butt joint by flashing action andby the application of pressure after heating is substantially completed.
The flashing action, caused by the very high current densities at small contact points between the workpieces,
forcibly expels the material from the joint as the workpieces are slowly moved together.The weld is completed
by a rapid upsetting of the workpieces. The pieces are
67
AWS C l .1 M/C1.1:2OOO
~~~~
Table 44
Punch Design Data for Low-Carbon Steel Projections
'\
45"
+0.013 mm (0.005 in.)

A = RADIUS -0.000 mm (0.000 in.)
/-
4-
60.32 mm (2.375 in.)

STRAIGHT PUNCH
+0.013 mm
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
O.&^ in.)
+0.005 mm
(0.0002 in.)
D-0.010 mm
(0.0004 in.)
12.45 mm
14-
60.32 mm
in.) (2.375
SHOULDER PUNCH
Sheet Thickness
G 5 G5
4.80 mm
(0.189 in.)
4.70 mm
(0.185 in.)
L10.490 in.)
i2.10 mm
(0.480 in.)
0.5 mm R
(0.02 in.)
mm
(in.)
Qpe of Punch
mm
(in.)
mm
(in.)
0.61-0.76
0.91-1.52
1.70-2.29
(0.024-0.032)
(0.036-0.060)
(0.067-0.090)
Straight, Shoulder
Straight, Shoulder
Straight, Shoulder
0.51
0.64
1 .o2
(0.020)
(0.025)
6.35
9.52
9.52
(0.250)
(0.375)
(0.375)
(0.040)
General Notes:
1. All dimensions are in mm (in.).
2. The punches should be made from SAE M-2 steel, Hardness Rockwell "C" 60-63 and should be nitrided.
3. See Table 52 for projection size.. .
4. On straight punch, shank hardness should be 102-103 Rackwell "B."
5. G is ground surface.
68

AWSCl.lM/C1.1:2000
Table 45
Die Button Design Datafor Low-Carbon Steel Projections
+0.005 m m
"
"
"
L
-
//
""_
t'
G4
19.0 m m (0.75in.)
1
,
I
\
"8"
RADIUS REF.
1,
+o.oo
H-0.05 m m
(0.002in.)
0.76 m m (0.030in.) R
0.64 m m (0.025in.)
ENLARGED VIEW OF WELD PROJECTION

BUlTON DIE
B Radius Ref.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
mm
(in.)
mm
(in.)
mm
(in.)
mm
(in.)
mm
(in.)
9.53
9.53
9.53
12.70
12.70
12.70
15.88
15.88
15.88
15.88
(0.375)
(0.375)
(0.375)
(0.500)
(0.500)
(0.500)
(0.625)
(0.625)
(0.625)
(0.625)
1.30
1.52
1.73
2.03
2.34
2.64
3.20
3.58
4.22
4.85
(0.051)
(0.060)
(0.068)
(0.080)
(0.092)
(0.104)
(O. 126)
(0.141)
(O. 166)
(O. 1Y 1)
1.70
2.08
2.44
2.95
3.25
3.9 1
4.70
4.85
6.53
7.49
(0.067)
(0.082)
(0.096)
(O. 1 16)
(O. 128)
(O. 154)
(O. 185)
(O. 1Y 1)
(0.257)
(0.295)
2.29
2.67
3.05
3.56
4.06
4.57
5.33
6.10
7.37
8.13
(0.OYo)
(O. 105)
(O. 120)
(O. 140)
(O. 160)
(0.180)
(0.210)
(0.240)
(0.2Yo)
(0.320)
0.69
0.81
0.94
1 .O7
1.19
1.32
1.45
1.70
1 .Y6
2.21
(0.027)
(0.032)
(0.037)
(0.042)
(0.047)
(0.052)
(0.057)
(0.067)
(0.077)
(0.087)
General Notes:
1. All dimensions are in mm fin.).
2. The dies should be made from'SAE A-2 sleel, hardness Rockwell "C" 58-62.
3. See Table 52 for projection sizes and Table 44 for punch dcsign data.
4. G is a ground surface.
69

AWS Cl .1M/Cl.l:2oOO
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--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


AWS Cl.lM/C1.1:2000
Table 47
Projection Welding Parameters for Low-Carbon Steel'
Projection Size
Stock Thickness
mm (in.)
Diameter
mm (in.)
0.51-0.71 (0.0200.028)
0.79-0.91 (0.031-0.036)
(0.0374.048)
1.27-1.55 (0.0500.061)
1.57-2.03 (0.062-0.080)
2.08-2.44 (0.082-0.096)
2.54-3.10 (0.100-0.122)
(0.1254.150)
2.67 (0.105)
3.05 (0.120)
Height
mm (in.)
1.02 (0.040)
4.06 (0.160)
(0.045)
4.57 (0.180) 1.27 (0.050)
5.33 (0.210) 1.40 (0.055)
6.10(0.240) 1.65 (0.065)
7.11(0.280)3.18-3.81
Net
Electrode
Force
Welding Current
Minimum
Amps Welding
Time
Spacings
kN (Ib)
Cycles4 Low
High
mm (in.)
0.67 (150) 0.763-4
(0.030) 3 O00 5 O00 9.6 (0.38)
4
O00 6 000 412.7 (0.50)
0.89 (200) 0.89 (0.035)
5
5 000 7500 lg.O(O.75)
1.33 (300)
3.56
(0.140) 0.94-1.22
6 500 9 500 19.0 (0.75)
2.00 (450) 1.14 7
10
7 500 11 O00 22.4 (0.88)
2.89 (650)
9 000 13 O00 26.9 (1 .Oh)
13
4.00 (900)
16
10000 14 500 31.8 (1.25)
4.96(1150)
6.01 (1350) 1.9019(0.075)11 500 16 500 38.1 (1.50)
Minimum
Shear
Strength
kN (Ib)
2.67 (600)
4.67 (1050)
5.78 (1300)
8.01 ( 1800)
10.79 (2430)
14.46 (3250)
17.13 (3850)
21.35 (4800)
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
General Notes:
1. This table is to be used in conjunction with Table 52 which gives the sheet thickness combinations that correspond to theprojection sizes shown.
2. Electrodes: R W M A Class 2, truncated cone shape with 20" bevel and face diameter of 3 times the projection diameter.
3. For multiple projection welding, multiply the force and current by the number of projections to be welded but keep the welding time consvant.
4. Based on single-phase a-c 60 Hz equipmcnt.
5. Minimum weld spacing is measured from Centerline to centerline.
Table 48
Projection Welding Parameters for Galvanized Low-Carbon Steel'
Minimum
TcnsionSatisfactory
Shear
Material
Welding Welding
Nugget
Time
Strength
Thickness
Current Force
Diameter
Diameter
Height
kN (Ib)
Cycles
mm (in.)
Amps
mm (in.)
mm (in.)
mm (in.)
15
0.99 (0.039) 15.88 (0.625) 9.52(0.375)1.1 I (250) 10000
3.8 (0.15) 4.75 (0.187) 1.04 (0.041) 4.1 1 (920)
20
1.35 (0.053)
1.22(0.25)
(0.048) 9.12 (2050)
1.78 (400)
5.54 (0.218) 6.4
11.13 (0.438) 15.88
(0.625)1 1 500
O00
12.01(2700)
25 16 6.4 (0.25)
(0.250) 1.37 (0.054) 6.35
1.98 (0.078) 19.05 (0.750) 12.70 (0.500) 2.45 (550)
Electrode2* Projection Size

Net
Electrode
Facc
Body
Diameter Diameter
mm (in.)
kN (Ib)
mm (in.)
2.36 (0.093) 19.05 (0.750)

2.77 (0.109) 22.22 (0.875)
3.34 (750) 12.70O00

(0.500) 30 16
33 22 000
(0.500) 4.23 (950) 12.70
(0.054) 19.13 (4300)

6.35 (0.250) 1.37
7.6 (0.30)
(0.054) 21 .SO (4900)
6.35 (0.250) 1.37
7.9 (0.31)
Gcneral Notes:
1. Welding parameters are applicable for projection welding galvanized low-carbon steel.
2. Welding parameters are applicable using electrode malerials included in R W M A Classes 1.2, and 20.
3. The wclding electrode design that the above parameters apply to include a flat face with a 20-degree bevel.
Table 49
Projection Welding Parameters for Stainless Steels'
Sheet Thickness
mm (in.)
Electrode Face
Diameter'
(2 Times Proj. Diameter)
20" Bcvel
mm (in.)
Welding Current
(at Elcctrodcs)
Net Electrode
60 Cycles A-C
Force
Hold Time Weld Time (Approx.)
kN (Ib)
Cyclcs Cyclcs
Amps
7
15
4 500
1.3 (300) 3.2 (0.13) 0.36 (0.014)
15 10
4 750
2.2 (500)
15 15
5 750
3.1 (700)
0.53 (0.021)
4.0 (0.16)
0.79 (0.031)
4.8 (0.19)
1.12 (0.044)
6.4 (0.25) 3.1 (700)
1.57 (0.062)
5.3 (1200)
7.9 (0.31)
1.98 (0.078) 9.5 (0.37) 8.5 (1 900)
2.39 (0.094)
8.5 (IYOO)
11.1 (0.44)
2.77 (0.109)
12.5 (2800)
12.7 (0.50)
3.18 (0.125)
12.5 (2800)
14.3 (0.56)
20
15
6 O00
25
30
30
30
15
7 500
1o O00
10 O00
O00
O00
30
30
30
45 13
45 14
General Notes:
1. Types of steel: 309,310,3 16. 31 7,321, 347, and 349.
2. Electrode material: R W M A Class 2.3, or 12.
71

AWS Cl .1M/C1.1:2000
Table 50
Projection Designs and Process Requirements for Annular Projection
Welding Some Representative Light-Gauge Steels
Projection Welding of Low-Carbon' Steel2
0.28 mm to 0.48 mm (0.011 in. to 0.019 in.) Thickness (Two Equal Thicknesses)
Tensile-Shear Strength6
Each Projection
Minimum
mm (in.)
Contact
Overlap Spacing
mm (in.)
7.9 (0.31)
7.9 (0.31)
6.4 (0.25)
6.4 (0.25)
Minimum
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
Thickness
mm (in.)
0.28 (0.01 1)
0.48 (0.019)
Electrode4 Weld3
Weldings
kN (Ib) Cycles Amps
6
6
0.50 (1 10)
1.O0 (225)
5200
5400
or More
One CurrentTwo
Force
Time
kN (Ib)
kN (Ib)
0.85 (1 90)
0.65 (145)
1.78(400) .
1.25 (280)
General Notes:
1 , Low-carbon s t e e l S A E 1010-290-380 MPa (42-55 ksi) ultimate tensile strength.
2. Surface of steel may be oiled lightly but free from grease, scale and dirt.
3. Based on 60 Hz.
4. Electrode force contains no factor to further form poorly made parts.
5. Starting values shown are based on experience of member companies.
6. Approximate strength per projectiondepends on joint design.
welded in a butt joint and have similar shapes and crosssections. The two piece are clamped in current conducting dies which form part of the electrical circuit of the
machine. Light contact is made between the pieces, anda
high current is established through the circuit, causing
local points of contact to be heated beyond the melting
point.
Proper flashing action is maintained by moving the
work together at a controlled rate. When the surfaces to
be joined become sufficiently plastic,they are rapidly
forged together under high force, displacing the hot
metal in the form of an upset. The molten metal is expelled resulting in a solid-state joint. This upset action, in
addition to producing the weld, closes all craters formed
during flashing and expels oxides and impurities from
the weld.
or pneumatic controls. A constant acceleration will provide increased heating withreduced material loss.
6.2.2 Secondary Voltage and Current. The secondary voltage during flash time may be controlled by
means of taps on the welding transformer. Phase shift
control should not be used tocontrol flash voltage or current. During upset or postheat, phase shift control using
silicon controlled rectifier (SCR) or ignitron tube controls may be used to adjust current.
6.23 Timing. Upset current and force timing may be
controlled by means of cams, limit switches, or electronic controls. Flash time is to be controlled by the
platen feed system.
6.2.4 Electrodes. The electrodes should be of adequate size and should be so fitted to the surfaces of the
workpieces to be weldsd that alignment of the workpiece
cross-section is properly maintained and the necessary
current will be uniformly distributed about the contact
surfaces. The electrode material should be capable of
conducting current to the workpieces without damage
due to localized overheating.
6.2 Equipment. Welding equipment varies in the methods used to conduct the welding current and apply the
welding force to the workpiece. All equipment must be
capable of bringing the workpieces together in a controlled manner and automatically regulating the feed of
the workpieces (rate and distance of travel), the secondary voltage and current and the timing of the application
of current and upset force.
6.3 Welding Variables. Flash welding involves a large

number of variables. These variables are listed and defined here along with a variable definition chart (see Figures 27 and 28) and not in Terms and Definitions (see
Section 2). It should be realized that not all equipment
nor all welding schedules can use all of these variables.
6.2.1 Platen Feed. The platens must be advanced toward each other in order to maintain flashing. Manual
flashing should be restricted to less than 15 percent of the
total flash time. Automatic flash feed may be effectedby
cam followers, servo motor drives, hydraulic actuators,
72

AWS Cl .1 M/C1.1:2000
Table 51
Projection Welding Design Datafor Stainless Steels"
+_
T
T
Thickness T
Diameter of
of Thinnest
Outside Piece Projection D
(See Notes7,
(Nominal)
8, and 10
(See Notes 1,2,
below)
3, and 4 below)
mm (in.)
mm (in.)
0.25 (0.010)
0.30 (0.01 2)
0.36 (0.014)
0.41 (0.016)
0.53 (0.021)
0.64 (0.025)
0.79 (0.031)
0.86 (0.034)
1.12 (0.044)
1.27 (0.050)
1.57 (0.062)
1.78 (0.070)
1 .Y8 (0.078)
2.39 (0.094)
2.77 (0.109)
3.18 (0.125)
3.56 (0.140)
3.96 (0.156)
4.34 (0.171)
4.75 (0.1 87)
5.16 (0.203)
6.35 (0.250)
1 . 4 0 (0.055)
1.40 (0.055)
(0.055)
2.06 (0.081)
2.39 (0.094)
(0.1 19)
10.31 (0.406)
13.49 (0.531)
Minimum Shear Strength

(Single Projections Only)
kN (Ib)
Height of
Projection H
(Sce Notes7,
9, and 10
below)
mm (in.)
'ensile Strength
480 MPa
(70 ksi) Up to
1.O3 GPa
(1 50ksi)
Tensile
Strength
Below
480 MPd
(70 ksi)
0.57 (130)
0.38 (0.015)
0.76 (1 70)
0.38 (0.015)
0.38 (0.015) 1.400.89 (200)
.O7 (240)
0.43 (0.017) 1.701(0.067)
(320)
0.43 (0.017) 1.70 1.42
(0.067)
2.00 (450)
0.51 (0.020)
(630)
0.56 (0.022) 2.392.82
(0.094)
3.51(7")
0.56 (0.022)
0.71 (0.028) 3.024.09
(0.1 (920)
19)
0.71 (0.028) 3.026.01 (1 350)
(1 950)
0.89 (0.035) 3.968.67
(0.156)
10.23
(2 300)
0.89 (0.035) 3.96
(0.156)
(2 700)
1.04 (0.041) 4.7512.01
(0.187)
15.34
(3 450)
1.22 (0.048) 5.54
(0.218)
(4 150)
1.37 (0.054) 6.3518.46
(0.250)
(4 800)
1.60 (0.060) 7.1421.35
(0.281)
1.67 (0.066) 7.9226.69
(0.31(62)OOO)
33.36 (7 500)
1.83 (0.072) 8.71 (0.343)
(8 500)
1.98 (0.078) 9.5237.81
(0.375)
44.48 (1 O O O O )
2.16 (0.085)
53.38
(12 000)
2.31 (0.091) 11.10
(0.437)
66.72 (15 0 0 )
2.79 (0.110)
0.80 (1 80)
0.98 (220)
1.25 (280)
1.47 (330)
1.Y6 (440)
2.67 (600)
3.78 (850)
4.45 (1000)
5.78 (1300)
7.56 (1700)
10.01 (2250)
12.45 (2800)
1.42 (3200)
17.79 (4000)
22.24 (5000)
25.35 (5700)
"
Tensile
Strength
1.O3 GPa
(150 ksi)
and Above
1.11 (250)
1.47 (330)
1.69 (380)
2.00 (450)
2.67 (600)
3.65 (820)
4.89 (1 100)
5.78 (1300)
8.W (2000)
10.68 (2400)
15.12 (3400)
18.68 (4200)
21.35 (4800)
27.13 (6100)
31.14 (7000)
35.59 (8000)
"
"
"
"
"
"
"
"
"
"
"
Minimum
Nugget
Diameter
(at Weld
Interface)
mm (in.)
2.48 (O. 112)
2.48 (0.1 12)
2.48 (O. 1 12)
2.48 (O. 112)
3.56 (0.140)
3.56 (0.140)
4.29 (0.169)
4.29 (0.169)
4.29 (0.169)
5.72 (0.225)
5.72 (0.225)
7.14 (0.281)
7.14 (0.281)
7.14 (0.281)
8.59 (0.338)
8.59 (0.338)
11.1 (0.44)
12.7 (0.50)
14.3 (0.56)
14.3 (0.56)
16.0 (0.63)
17.5 (0.69)
Minimum
Contacting
Overlap L
(See Notes 5
and 6 below)
mm (in.)
3.2 (0.13)
3.2 (0.13)
3.2 (0.13)
4.0 (0.16)
4.0 (O. 16)
4.8 (O. 19)
5.6 (0.22)
5.6 (0.22)
7.1 (0.28)
7.1 (0.28)
9.5 (0.37)
9.5 (0.37)
11.1 (0.44)
12.7 (0.50)
16.0 (0.63)
17.5 (0.69)
19.O (0.75)
20.6 (0.81)
22.2 (0.87)
23.8 (0.94)
25.4 (1.OO)
31.8 (1.25)
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
General Notes:
1. Stainless steel types:3OY, 310,316,317,321,347, and 349.
2. Material should be free from scale, oxides, paint, grease, and oil.
3. Size of projection normally determined by thicknessof thinner piece, and projection should be on thicker piece where possible.
4. Data basedon thickness o f thinner sheet, and for two thicknesses only.
5. Contacting overlap does not include any radii from forming, etc.
6. Weld should be locatedin center of overlap.
7. Projection should be made on piece of higher conductivity when dissimilar metals are welded.
X. For diameter of Projection D a tolerance of 20.0X mm (20.003 in.) in material up to and including 1.27 mm (0.050 in.) in thickness and 20.20 mm
(zO.O()X in.) in material over 1.27 mm (0.050 in.) in thickness may be allowed.
9. For weight of Projection H a tolerance of 20.05 (20.002 in.) in material up to and including 1.27 mm (0.050 in.) in thickness and k0.13 mm
(~0.0()5in.) in material over 1.27 mm (0.050 in.) in thickness may be allowed.
10. See Table 46 for data on punch anddie designs for making projections.
73

Table 52 (Page 1 of 2)
Projections for Low-Carbon Steel
DIESFOR BUTTON
45
TABLE
SEE
H +0.05 mm
(0.002 in.)
-0.10 mm
(0.004 in.)
SPACINGMINIMUM
FOR PUNCHES
TABLE
SEE
44
I2 D
10.2 mm (0.400 in.) OR 2 4

WHICHEVER IS GREATER
0.76 mm R
(0.030in.)
0.64 mm
(0.025 in.)
0.71 0.56
(0.028)(0.022)
D 4.57(0.180)4.06(0.160)4.06(0.160)
3.56 (0.140) 3.56 (0.140) 3.56 (0.140) 3.56 (0.140) 3.05 (0.120) 3.05 (0.120) 3.05 (o.120)
H 1.27 (0.050) 1.14 (0.045) 1.14 (0.045) 1.02 (0.040) 1.02 (0.040) 1.02 (0.040) 1.02 (0.040)0.89 (0.035) 0.89 (0.035) 0.89 (0.035)
0.71
(0.032)(0.028)
D 4.57 (0.180) 4.M (O. 1 6 0 ) 4.(6 (0.160) 3.56 ( 0 . 1 4 0 ) 3.56 (0,140) 3.56 (0.140) 3.56 (0.14)) 3.05 (0.120) 3.05 (0.l2n) 3.05 (0.lU))
H 1.27 (0.050) 1.14 (0.045) 1.14 (0.045) 1.02 (0.040) 1.02 (0.040) 1.02 (n.nq 1.02 (0.040) 0.89 (0.035) 0.89 (0.035) 0.89 (0.035)
~~~~
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
0.81
74

AWS Cl.lM/Cl.1:2000
Table 52 (Page 2 of 2)
Projections for Low-CarbonSteel
FOR BUTTON DIES
SEE TABLE 45
H +0.05 mm
(0.002in.)
-0.10 mm
(0.004 in.)
FORPUNCHES
SEE TABLE 44
MINIMUM SPACING
10.2 mm (0.400 in.) OR 2D,
WHICHEVER IS GREATER
UD
0.76 mm R
(0.030in.)
0.64mm
(0.025 in.)
General Notes:
1 . See Table 44 for punch design data, Table45 for die design deta, and Table47 for welding schedules.
2. Whcn lhe lhickncss rialio of Ihc picccs t o hc wcldcd is 4-10-1 orgrcillcr, thc projcctions should hc on thc thickcr piccc.
3. See RWMA for additional information on heavier gauge material.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
75

Table 53
Process Requirements for Cross-Wire Welding a Range of
Thicknesses of Hot- and Cold-Drawn Steel Wires
Tabulated Strengthsof Cross-Wire Welds For Specified Percentagesof Setdown
Cold-Drawn Wire
Wire
Diameter
mm (in.)
Weld
Cycles
Hot-Drawn Wire
Weld
Welding
Force Time Current'
kN (Ib)
Strength
kN (Ib) AmpsCycles
Weld Weld Welding

Weld
Weld
Current ForceStrength
Time
kN (Ib)
kN (Ib) Amps
15 Percent Setdown
5
600
600
1.6 (0.06)
3.2 (0.13)
10
0.44 (100)
0.56 (1 30)
1 800
2.00 (450)
4.34 (980)
5
10
0.44 (100)
0.56 (130)
1 850
1.56 (350)
3.34 (750)
4.8 (O. 1 9)
6.4 (0.25)
17
23
1.60 (360)
2.56 (580)
3300
4500
8.90(2000)
l6.46(3 700)
17
23
1.60 (360)
3.36 (580)
3 500
4 900
6.67 (1 500)
12.46 (2 soo)
7.9 (0.31)
9.5 (0.37)
30
40
3.67 (830)
4.89 (1100)
6 000
7000
22.69 (5 100)
29.80(6700)
30
40
3.67 (830)
4.89 (1100)
6 600
7 700
20.46 (4 600)
27.59 (6 200)
11.1 (0.44)
12.7 (0.50)
50
60
6.23(1400)
7.56(1700)
9 300
10300
42.70(9600)
54.27 (12000)
50
6.23 (1400)
7.56 (1700)
11 000
39.14 (8 800)
51.15 (11 500)
60
10 000
30 Percent Setdown
1.6 (0.06)
3.2 (0.13)
5
10
0.67 (1 50)
1.16 (260)
2650
2.22 (500)
5.00(1 120)
10
0.67 (150)
1.16 (260)
800
2 770
1.78 (400)
3.78 (850)
4.8 (0.1 9)
6.4 (0.25)
17
23
2.67 (600)
3.78 (850)
5000
6700
10.68(2400)
18.68 (4200)
17
23
2.67 (600)
3.78 (850)
5 100
7 100
7.56 (1 700)
13.34 (3 000)
7.9 (0.31)
9.5 (0.37)
30
40
6.45 (1450)
9. 16 (2060)
9300
11 300
27.13(6 100)
37.81 (8 500)
30
40
6.45 (1450)
9.16 (2060)
9 600
11 800
22.24 (5 000)
30.25 (6 800)
11.1 (0.44)
12.7 (0.50)
50
60
12.90 (2900)
15.12 (3400)
13 800
48.93 (1 1 000) 50
60.50 (1 3 600) 15 60
12.90 (2900)
15.12 (3400)
14 000
16 500
42.70 (9600)
55.16 (12400)
800
800
50 Percent Setdown
1.6 (0.06)
3.2 (0.13)
5
10
0.89 (200)
1.56 (350)
1 000
3 400
2.45 (550)
5.56(1 250)
10
0.89 (200)
1.56 (350)
1000
3 500
4.00 ('HK))
4.8 (0.19)
6.4 (0.25)
17
3.34 (750)
5.52 (1240)
6000
23
8 600
11.12(2500)
19.57 (4 400)
17
23
3.34 (750)
5.52 (1 240)
6 300
9 000
8.00 (1 800)
13.79 (3 100)
7.9 (0.31)
9.5 (0.37)
40
8.90 (2000)
13.34 (3000)
11 400
14400
28.91 (6 500)
39.14 (8 800)
40
8.90 (2000)
13.34(3000)
12 000
14 900
23.58 (5 300)
32.03 (7 200)
19.79 (4450)
22.24 (5000)
17400
21000
52.93 (11 'HK))

64.94 (14 600)
19.79 (4450)
23.58 (5300)
18 000
22 O00
45.37 (10 200)

57.83 (13000)
11.1 (0.44)
12.7 (0.50)
30
50
60
30
50
h0
2.00 (450)
General Note:
1. Starling values shown are basedon experience of member companies.
76
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


AWS Cl .1 M/C1.I :2000
no postheat is used) to the time when the clamping

force is released from the workpieces.
flash is the material that is expelled from a flash weld

prior to the upset portion of the welding cycle.
flash current(rms. A) is the total rms current impulseor
series of impulses that occur through the workpieces
during flashing.
flash time (s) is the duration of flashing action during
flash welding.
flash voltage(rms. V) is the total rms voltage that occurs

across the workpieces during flashing.
final extension, material X (N,mm [in.]) is the dimension from the die which clamps Material X to the
Weld Line at the completion of the weld.
BEFORE WELDING
final extension, material Y (P, mm [in.]) is the dimension from the die which clamps Material Y to the
Weld Line at the completion of the weld.
1
B
final fixture opening ( C , mm [in.]) is the distance between the upper and lower fixture at the completion
of
the weld.
AFTER WELDING
"PERCENTAGE
SETDOWN"
initial extension, materialX (L, mm [in.]) is the dimension from the die which clamps Material X to that
point on Material X which first contacts Material Y.
100
A = SAME DIAMETER AS C OR SMALLER
initial extension, material Y (M, mm [in.]) is the dimension from the die which clamps Material Y to that
point on Material Y which first contacts Material X.
Figure 25-Diagram Defining How SetDown is Estimated on Cross-Wire Welds
initial fixture opening (A, mm [in.]) is the distance between the upper and lower fixture when the workpieces first make contact.
A form for recording flash welding data is found in Fig-
instantaneous rate of flash-loss (m/s [in./s]) is the instantaneous velocity of one workpiece relative to the
other during flashing action and is the first derivative
of such motion at a specified position.
ure 36.
automatic flash-loss (F, mm [in.]) is the length of material that is consumed in flashing while the flashing is
controlled automatically.
instantaneous velocity of upset (m/s [in./s]) is the instantaneous velocity of one workpiece relative to the
other during upsetting action and is the first derivative
of such motion at a specified position.
average rate of flash-loss(m/s [in./s]) is the average velocity of one workpiece relativeto the other during the
entire flashing action.
material loss (B, mm [in.]) is the total length of material

that is consumed in making the weld.
average velocity of upset (m/s [in./s]) is the average velocity of one workpiece relative to the other during the
entire upsetting action.
automatic flash time (s) is the time during which flashing by automatic control is taking place.
manual flash-loss(E, mm [in.]) is the length of material

that is consumed in flashing while the flashing is controlled manually.
clamp force (newton [Ib-f]) is the force exerted on the

dies by the clamping system.
manual flash time (s) is the time during which flashing

by manual control is taking place.
clamp-holding time ( s ) is the time measured from the

end of postheat time (or end of upsetting time when
material X loss (J, mm [in.]) is the length of Material X

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

77
TI
PRONOUNCED
BULGE
AFTER
BEFORE
SHORT
WELD
TIME,
FULL-WIDTH
PROJECTION
CORRECT
WELD
TIME,
FULL-WIDTH
PROJECTION
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
EXTENSIVE
BULGE
OT
ER
BEFORE
EXCESSIVEWELDTIME,FULL-WIDTHPROJECTIONCORRECTWELDTIME,REDUCEDWIDTHPROJECTION
EXCESSIVE WIDTH OF THE PROJECTION CAN RESULTIN UNSTABLE PROJECTION
COLLASPE, AND FORMATION OF INCIPIENT NOTCHESAT THE BASE OF THE JOINT.
Figure 2fGCharacteristics of Projection Collapse during

Annular Projection Welding with Different Base-Projection Widths
material Y loss (K,mm [in.]) is the length of MaterialY

postheat voltage (rms. V) is the total rms voltage that

occurs across the workpieces during postheating.
platen force (newton [Ib-fl) is the force available at the

movable platen to cause upsetting. This force may be
dynamic, theoretical, or static.
preheat current(rms. A) is the total rms current impulse

or series of impulses that occur prior to initiation of
flash current.
postheat current (rms. A) is the total rms current impulse or series of impulses that occur through the
workpieces duringpostheating.
preheat voltage (rms. V) is the total rms voltage that occurs across the workpieces prior to initiation of flash
current.
postheat time( s ) is the time during which postheating is

taking place.
preheat loss (G,mm [in.]) is the length of material that

is consumed as aresult of the preheating action.
78


AWS Cl .1 M/C1.1:2000
FINAL DIE
OPENING
-FINAL
EXTENSION
(C)
(E) -
,-TOTAL
MATERIAL
LOST
FINAL
EXTENSION
, , / , ,
MATERIAL Y
//
MATE
4 LOS
//
rOTAL
IT (H) -
MANUAL
FLASH OFF
1-
-AUTOMATIC +
FLASH OFF
FLASH OFF (F)
TRAVEL
INITIAL DIE OPENING (A)
DIMENSIONS
Figure 27-Chart
of Flash Welding Definitions
79

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
AWS C l .1MICI .I :2000
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
POSTHEAT
CURRENT7
C4
TIME"
TIME AT V1
W-
*-"PREHEAT
TIME"
4
TIME"
SVGt
"CLAMP
"UPSET CURRENT TIME"
MANUAL
"POSTHEAT
"FLASH
TIME"
TIME"
AUTOMATIC "FLASHTIME"
'FLASH
WELD TIME"
+'UPSET
TIME"
WELDING PERIOD
Figure 2S"Chart of Flash Welding Definitions
preheat force (newton [Ib-fl) is the force exerted on the

welding surfaces during preheating.
travel at 1, (Q, mm [in.]) is the dimension the movable

platen (Material Y) travels during flashing current I,.
preheat time (s) is the duration of preheat current flow

during the preweld interval.
travel at I2 (R,mm [in.]) is the dimension the movable

platen (Material Y)travels during flashing current IF
secondary voltage(rms. V) is the open-circuit voltageof

the welding transformer measured on the secondary
side with no phase shift.
upset current time (s) is the time during which upsetting current flow is taking place.
upset time(s) is the time during upsetting.
spring-back (mm) [in.]) is the deflection of the welding

machine when making the weld.
upset voltage (rms. V) is the total rms voltage that occurs across the workpieces duringupsetting.
time at flash current I, (s) is the time during which

flashing with current I , is taking place.
weld line is the plane of fusion of the welded parts.

weld time (s) is the timeduring which flashing and upset
are taking place.
time at flash current I2 ( s ) is the time during which

flashing with current 12 is taking place.
upset force (newton [lb-f]) is the force exerted at the

welding surfaces during upsetting.
total flash-loss (D,mm [in.]) is the total length of material that is consumed in flashing.
upset current (rms. A) is the total rms current impulse

or series of impulses that occur through the workpieces during upsetting.
total upset (H,mm [in.]) is the length of material that is

consumed as aresult of the forging action.
80

AWS Cl .lM/C1.1:2000
The Flash Current is very irregular due to the flashing

action of the weld. While an oscillograph record may
provide an indicationof this current, such recordsare difficult to analyze readily. To transfer data from one welding schedule to another it is necessary to use an rms
current measuring device that is synchronized in time
with the current.
6.4 Welding Variable Measurements

6.4.1 Dimensional Measurements. The dimensions
below are usually obtained by scale measurement of the
workpieces before and after welding.
(1) Material X loss
(2) Material Y loss
(3) Initial Extension-Material X
(4) Initial Extension-Material Y
(5) Final Extenson-Material X
(6) Final Extension-Material Y
The followingdimensionsareusuallyobtained
by
scale measurement of such items on the welding machine.
(1) Initial Fixture Opening
(2) Final Fixture Opening
(3) Total Flash-loss
(4) Manual Flash-loss
(5) Automatic Flash-loss
(6) Preheat loss
(7) Travel at Initial Current (I,)
(8) Travel at Flashing Current (12)
The Total Upset (H) may be measured by subtracting
the sum of the measurements of Total Flash-loss (D) and
Preheat Loss ( G ) from the measurementof Material Loss
6.4.5 Voltage Measurements. Secondary Voltage can

be measured with weld voltage monitoring equipment.
The use of average and/or peak measuring equipment
should be avoided.
6.4.6 Rates and Velocitiesof Flash-Loss and Upset.
The Average Rate of Flash-Loss can be calculated from
the Flash-Loss Time and Total Flash-Loss.
The Instantaneous Rate of Flash-Loss, Instantaneous
Velocity of Upset, and Average Velocity of Upset can be
measured by the use of any device which will satisfactorily record mechanical motion and time.
6.4.2 Time Measurements.The following time intervals may be obtained by direct measurement with a stopwatch, or can be obtained from an instrument such as an
oscillograph, recording ammeter, recording wattmeter,or
welding monitor.
(1) Preheat
(2) Manual Flashing
(3) Automatic Flashing
(4) Time at Flash Current 1,
(5) Time at Flash Current l2
(6) Welding Cycle
(7) Quench or Cool
(8) Postheat
(9) Clamp Holding
6.43 ForceMeasurements. The PlatenForceand
Upset Force are of a transient nature and are influenced
by the method of applying the forces, and
by friction, inertia, and theopposing reaction of the material being upset.
Consequently, it is difficult to obtain precise measurement of such forces without strain gauges or load cells.
The ClampingForce is usually calculated, the effectof
friction being considered when making such calculations.
6.4.4 Current Measurements.Preheat Current, Flash
Current, Upset Current and Postheat Current can be measured with weld current monitoring equipment.
6.6 Joint Preparation and Cleaning.The mating parts

should be prepared in such a manner that the heat generated will be uniformly distributed over the section. Figures 29 and 30 show recommended end preparation for
flash welding of flat sheet, tubing, solid round, hexagonal square, and rectangular bars.
Welding of tubing with a ratio of outside diameter to
wall thickness greater than 30:l is difficult and therefore
not recommended. Additionally, welding of sheet with a
width to thickness ratio of greater than 400:l is difficult
and therefore not recommended.
81

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
(X).
6.5 Classification of Steels for Flash Welding.The values of the upset forces required for various sections of various steels are related to the temperature gradient of the
workpieces in the plastic zone and to the compressive
strengths of the steels at these elevated temperatures. For
consideration in applying the flash welding process to
steels, such steels and their classes are grouped
as follows:
(1) Low-Forging Strength Steels. This class is typified by SAE 1020, 1112, 1315, and those steels commonly designated as high-strength low-alloy (HSLA)
steels.
(2) Medium-ForgingStrength Steels. This class is
typified by SAE 1045, 1065, 1335, 3130, 3135, 4140,
8620, or 8630.
(3) High-Forging Strength Steels. This class is typified by SAE 4340 and 4640, stainless steel (12 percent
chromium type), stainless steel (18-8 cutlery type), high
speed steel, or tool steel.
(4) Extra-High Forging Strength Steels. This class is
typified by all steels exhibiting extra high compressive
strengths at elevated temperatures, such as A-286 and
19-9DL.
A=
B=
C=
D=
INITIAL
OPENING
DIE H
MATERIAL
LOST
FINALDIEOPENINGL
TOTAL
FLASH-OFF
O.D.
= TOTAL
UPSET
J = K = MATERIAL
LOST
PER
PIECE
ELECTRODE
CONTACT
= M = INITIALEXTENSIONPERPIECET
= OUTSIDE
DIA.
OF
TUBING
S = MINIMUM
NECESSARY
LENGTH
OF
= TUBEWALL OR SHEETTHICKNESS
Figure 29-Flash Welding of Tubing and Flat Sheets
cl
I
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
OF
tt
ELECTRODE
A = INITIALDIEOPENING
B = MATERIAL LOST
C = FINAL DIE OPENING
FLASH-OFF
D = TOTAL
H = TOTALUPSET
J = K = MATERIALLOSTPERPIECE
L = M = INITIALEXTENSIONPERPIECE
O.D. = OUTSIDE DIA. OF ROIJNDS OR MlNlldUM

DIMENSION OF OTHER SECTIONS
S = MINIMUM NECESSARY LENGTH
Figure 30-Flash Welding of Solid Round, Hex, Square, and Rectangular Bars
82

S T D - A W S C L * L M / C Z = L - E N G L 2000
0761(2b5 0513738 7b2

AWS Cl .l MICI .I :2000
6.8 Weld Discrepancies and Causes.Effective problem-
The surfaces of the parts contacting the dies and the

surfaces to be welded should be clean and free from oxides, paint, grease, dirt, or foreign matter which would
interfere with the passage of current through the workpiece. Chemical cleaning and grit blasting are preferred.
Grit blasting should be followed by treatment to remove
imbedded particles prior to welding.
solving in flash welding requires a knowledge of weld

discrepancies and their causes. Generally, the solution
becomes obvious once thecause of the discrepancy is determined. The following are typical flash weld
discrepancies and their possible causes:
(1) Cracks (usually in the upset metal)
Metal not sufficiently plastic during upset
Inadequate die opening
Inadequate weld time
Inadequate upset current
Cracks totally in theupsetmetalareconsidered
acceptable because the upset metal is usually removed
after
welding.
(2) Weld Misalignment
Clamp dies misaligned
Clamp dies inadequately tightened
Backstopsmisaligned
Excessive welding machine deflection
Clamp dies excessively worn
Parts misaligned before welding
(3) Flat Spots, Penetrators (Oxide Inclusions)
Improper flashing acceleration just before upset
Inadequate upset force or upset velocity
Inadequate upset travel
Inadequate flash travel
Early cut off of flash current
Erraticflashingcaused
by excessive flashing
voltage, excessive or inadequateflashing acceleration
(4) Die Burns (overheated areas in the workpiece at
the location of the dies)
Insufficient contact area between the die and the
workpiece for the magnitudeof current being passed
Foreign material between the die and workpiece
or surface contamination
Insufficient clamping force
(5) Inadequate Weld Strength
Improper upset travel
Upset force too low
Partsslipped in clamp dies dueto inadequate
clamp force or backup
Improper flashing velocityor acceleration
Flashing voltage too high
Flash current phase shifting
Current shut off too soon before upset
Misaligned clamp dies
Final die space too large (aluminum welding)
Flash time too short
Defects in metal being welded
6.7 Welding Schedules. The data shown in Tables 54

and 55 and Figures 29 and 30 are offered as a guide for
developing flash welding schedules for various steels.
Flash welding schedules for welding steel tubing and flat
sheets having a thickness ranging from 0.25 to 25 mm
(0.010 to 1.00 in.) are given in Figure 29 and Table 54
and cover steels of low and medium forging strengths.
Flash welding schedulesfor welding solid round, hexagonal, square, and rectangular steel bars having a diameter, for round bars, or minimum dimension, for other
shaped bars, ranging from 1.3 to 50 mm (0.050 to 2.00
in.) are given in Figure 30 and Table 55 and cover steels
of low and mediumforging strength. Refer to 6.3 for definitions of process variables.
These schedules show the necessary dimensions for
setting up a flash welding machine to weld such sections
and the total flash time based on welding without preheat. No data are given on the flash current, rates and velocities of flash and upset required due to the varying
types of equipment used.
When setting up a schedule, the dimensional variables
and flash time are selected from the tabulations. The machine voltage regulator is adjusted to give the lowest secondary voltage at which steady and consistent flashing
can be maintained. The flash current resulting from such
a voltage setting will then be at a satisfactory value. The
secondary voltage to obtain this satisfactory flash current
is dependent on the electrical characteristics of the welding machine being used.
The upset forces used for the schedules are dependent
upon the class of steel as well as the section being
welded.
Experience indicates that the selection of equipment
should be based on the following values
of recommended
platen force, and such values are based on the welding
heat being attained solely by flashing using no preheat:
Low forging strength s t e e l s 4 9 MPa (10 ksi) of weld
cross-sectional area.
Medium forging strength steels-103 MPa (15 ksi) of
weld cross-sectional area.
High forging strengthsteels-172MPa
(25 ksi) of
Extra high forging strength steels-241 MPa
(35 ksi)
It should be noted that the most common applications
use no preheat or dual flash currents, but consist of flashing at a single current followed by upset.
6.9 Weld Quality and Mechanical Property Tests

6.9.1.1MetallographicTest. Metallographicexamination should be used to evaluate flash welded joints
83
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---


EE
84

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
E:
II
el
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
85

STD-AWS CLILM/CL*L-ENGL 2000

AWS Cl.lM/C1.1:2000
tire area of faying surfaces or progressively along a butt

joint by the heat obtained from the resistance to the flow
of welding current through the areawhere those surfaces
are in contact. Pressure is used tocomplete the weld. The
two pieces of metalare similar in cross-section. Pressure
is applied before the current is started and maintained
throughout thejoining process.
Upset welding is similar to flash welding. The main
difference between the two processes is there is no flashing at the abutting surfaces in upset welding.
for soundness and microstructure duringwelding procedure development,It may also be used as a process control tool during production welding. One
or more sections
from a sample welded joint should be taken and polished,
etched, and optically examined for acceptability.
6.9.2 Nondestructive Weld Quality Tests. Fluorescent dye penetrant, radiographic, and ultrasonic inspections may be performed to determine the soundness of
flash welded joints. Additionally, magnetic particle inspection may be performed on flash welded joints of
magnetic metals. These inspections should be performed
after removal of the weld flash.
Since normallyspecifiednondestructiveinspections
may not adequately reveal the weld quality, proof load
testing should be performed on flash welded joints for
critical applications. A common proof test for flash
welded rings is to size the ring to provide a permanent
expansion of not less than 1 percent across a 50.8 mm (2
in.) gauge length centered on the weld. The test is performed after removal of the weld flash. For heat treated
rings, the test is performedafter cooling to room temperature from heat treatment.The test is performedin such a
way that the stress is uniformly distributed throughout
the ring. However, this test does not detect all defective
welds. A more stringent proof test should be used where
it is justified by the application.
7.2 Equipment. Thewelding equipment must be capable

of bringing the faying surfaces into intimatecontact, controlling the secondary voltageand current, and allowing
the welded joint to cool and achieve coalescence before
removing the welding force. Equipment is available for
welding:
(1) Two sections with the same cross-sectional area
and shape end-to-end.
(2) Longitudinal seams progressively along the butt
joint.
7.4 Joint Preparation and Cleaning.Machined faying

surfaces should be used because of the need for intimate
contact between them during welding. For thin sheets or
plates, the faying surfaces may be obtained by shearing.
They should be parallel when the workpieces are loaded
in the welding machine.
Prior to welding, the faying surfaces and those of the
workpiece contacting the dies should be cleaned to remove oxides, paint, grease, dirt, or foreign matter that
can contaminate the weld or impede the passage of current through the workpiece. Cleaning operations that
may leave a contaminant on the workpiece (e.g., grit
blasting), should be followed by an operation to remove
the contaminant.
7.5 Welding Parameters. Thedata shownin 6.7 for flash
welding of various steels and shapes, except those related
to producing flash, can be used as a guide to develop
upset welding schedules for the same steels and shapes
because of the similarity between the two processes.
7.6 Weld Quality and Mechanical Property Tests
7. Upset Welding
7.1 Introduction. Upset welding (UW) is a resistance

welding process that produces coalescence over the en-
7.6.1.1 Metallographic Test. As in flash welding,

metallographic examination should beused to evaluate
86

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
6.93 Mechanical PropertyTests. Standard mechanical

property tests for evaluating the base metals be
canused for
evaluating the mechanical properties
of flash welded joints.
The test specimen gage section should be centered on the
weld. For notched specimens, the notch shouldbe centered
on the weld. Weld joints which are heat treated before service should be tested in the heat treated condition.
Mechanical property tests, such as tensile and bendtests, may be performed to determine the deterioration in
performance of the welding machine with time. These
tests should be conducted on welded samples before, at
regular intervals during, and after a production run. The
test specimens should have the same cross-sectional area
in the weld area as the production parts to be welded, and
be of the same metal and heat treatment condition. The
specimens should be tested in full section whenever practical. Reduced section test specimens may be removed
from the welded joint if the full section is too large to
test. The reduced section specimen should contain at
least 50 percent of the original weld interface area. The
weld flash should be removed from both types of specimens to eliminate unsound metal from the weld.
7.3 Welding Variables. Because of the similarity between the two processes, upset welding has the same
basic process variablesas flash welding, except the flashing variables, The variable measurements can be the
same in both processes. The flash welding variables and
their measurements are described in 5.3 and 5.4, respectively. A form for recording upset welding data is found
in Figure 36.
AWS Cl .1 M/Cl.1:2000
upset welded joints for soundness and microstructure

during the welding procedure development. It may also
be used as aprocess control tool during production welding. One or more sections should be taken from a given
sample welded joint, polished, etched, and optically examined for acceptability.
7.6.1.2BendTest. A bendtestmaybeusedto
evaluate the quality of upset welds. A typical example of
a bend test uses a butt joint in a wire weld. The sample is
bent back and forth until it breaks. The weld quality is
considered acceptable if the fracture occurs outside the
weld.
7.63 Nondestructive Weld Quality Tests. Fluorescent liquid penetrant, radiographic, and ultrasonic inspections may be performed to determine the soundness
of upset welded joints. Additionally, magnetic particle
inspection may be performed on welded joints of magnetic metals.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
7.6.4 Mechanical Property Tests.

Standard mechanical property tests for evaluating the base metals can be
used to evaluate the mechanical properties of upset
welded joints. The test specimen gage section should be
centered on the weld. For notched specimens, the notch
should be centered on the weld. Welded joints which are
heat treated before service, should be tested i n the heat
treated condition.
Mechanical property tests, such as tensile and bendtests, may be performed to determine the deterioration in
performance of the welding machine with time. These
tests should be conducted on welded samples before, at
regular intervals during, and after a production run. The
welded sample should have the identical joint geometry
as the production parts to be welded, and be of the same
metal and heat treatment condition. The test specimen
taken from the sample should contain the full weld crosssection whenever practical. Reduced section test specimens may be removed from the welded joint, if the full
section is too large to test. When smaller size test specimens are used, they should contain at least 50 percent of
the original weld cross-section.
adhesive should be from the faying surfaces beneath the

electrodes during the build-up of electrode force prior to
the application of weld current. If a film adhesive is used,
there should be no adhesive in the areas to be resistance
welded because it impedes the flow of current between
the faying surfaces. Once the resistance welding operation has been completed, the assembly is then allowed to
cure in an oven or at ambient temperature, as recommended by the manufacturer.
Weld bonding has been employed for many years in
the aerospace industry for structural applications. In high
volume industries such as the automotive industry, the
same techniques have been used for non-structural applications involving weld-throughsealers. However, there is
a growing interest in these industries in the use of weld
bonding in place of resistance welding for structural applications involving both coated steels and aluminum alloys. The attractive features of using weld bonding
instead of exclusive resistance welding are higher static
shear strength, joint sealing, reduced vibration, improved
stress distribution, and fatigue strength.
8.2 Aluminum Alloys. Weld bonding of aluminum alloys has been conducted i n the aerospace industry for
many years, and consequently, most of the data available
has been generated in this area.
8.2.1 SurfaceCondition. The surface condition of

aluminum alloys has by far the greatest effect on static
shear strength and durability of weldbonded joints. The
two main requirements of static strength and durability
are both dependent on the character of the surface oxide
and are affected by surface contaminants. The normal
mode of deterioration of an adhesive bond in a hostile
environment is the introduction of moisture between the
bonding surfaces and the adhesive. The nature and porosity of the surface oxide has an affect on this mechanism.
For resistance welding, the surface should be clean and
have a low and consistent resistance. This can be
achieved by chemical or mechanical cleaning to remove
the oxide and surface contaminants as described in 4.3.
However, for weldbonded joints subject to exposure to
harsh environments, such as in military aircraft, chernically or mechanically cleaned faying surfaces would not
have adequate durability. For such applications, the surfaces should be preweld anodized. A low voltage anodizing treatment has beendeveloped, in conjunction with an
adhesive containing strontium chromate, to obtain the required bondline durability for aerospace applications.
This low voltage anodizing procedure is shown in Table
56. For joints not subject to exposure to harsh environments, chemically or mechanically cleaned faying surfaces may prove to be satisfactory.
8. Weld Bonding
8.1 Introduction. Weld bonding is a resistance spot
welding process variation i n which the spot weld
strength is augmented by adhesive at the faying surface.
It is the same as adhesive bonding except that resistance
welds are used to hold the components together during
the cure cycle instead of using autoclaves and tooling fixtures. A paste or film adhesive is placed between thesurfaces to be joined. Resistance welds are then made using
conventional equipment. If a paste adhesive is used, the
8.2.2 Weld Parameters. Anodized surfaces require

different welding parameters compared with chemically
87

AWS Cl.lM/C1.1:2000
Table 56
Weld-Bonding Surface Preparation for Aluminum Alloys by Low-Voltage Anodizing
Material I
Process
Vapor Degredse
1 1 1 ,Trichloroethylene
Vapor 60 sec.
Condensed fluid 60 sec.
Cool. Repeat until condensation
on part ceases
Alkaline Clean
Turco 42358: 45-60 gm/L
12-15 minutes,
63"-74"C (145"-16SF)
Cold deionized water
5-7 minutes
Amchem No. 7: Nitric acid

(Modified)
Nitric acid: 11-14% by
volume 42 (70% HN03)
Amchem No. 7 22-25 gm/L
Alodine No. 45: 3-3.2 ml/L
Alodine 1200E 3.5-3.6 ml/L
7-8 minutes. Room temperature

Agitated and filtered tank
Metal removal: 0.050-0.080
gm on 7.5 cm x 7.5 cm on 7075-T6
bare etched for20 minutes with
Cold tapwater
5 minutes
5-7 minutes
Phosphoric/Sodium dichromate
solution. Phosphoric acid: 9-12
ml/L (85% H3P04)
Sodium dichromate:Y-12 gm/liter
Deionized watcr: balance
20-22 minutes. Room temperature

Air agitated and filtered tank
5-7 minutes
Circulating hot air
65' f 5" C (150' f 10F)
Operation
Spray Rinse
Deoxidize
Spray Rinse
~
~~
~~
~~
~~~
no agitation
~~
Spray Rinse
Anodize
Spray Rinse
Oven Dry
1.4-1.6 volts for bare alloys
0.9-1.1 volts d-c for cladalloys
General Note:
1. Thcse malerials may be hazardous. Refer to the Manufacturer's Safely Ddld Sheet.
and mechanically cleaned surfaces. If a short duration,

high current pulse, as is used for chemically or mechanically cleaned surfaces, is used on anodized surfaces, expulsion will take place. To avoid expulsion, a long upslope current, short forge delay time, and high electrode
force should be used. Table 57 shows the difference in
welding parameters for spot welding and weld bonding
due to the surface condition and the addition of a paste
adhesive to the faying surfaces.
Anodized surfaces may require a change in the spot
weld spacing and the electrode maintenance requirements. The high contact resistance at the anodized faying
surface promotes a high shunting current through previously formed welds. Therefore, the weld spacing should
be at least 1.5 times greater than that for conventional
spot welding on nonanodized surfaces for the same applied weld schedule. With the anodized surface in contact with the electrode, the electrode pick-up will be
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

greater than that of conventional spot welding for the

same applied weld schedule. Electrode cleaning will be
required more frequently. Typical
welding parameters for
1.6 mm (0.063 in.) thick anodized 7075-T6 sheets are
shown in Table 58. Welding parameters for thinner or
thicker aluminum alloy sheets can be obtained by adjusting the welding heat. Neither the weld time nor the forge
delay time should be varied. However, the electrode
force and forge force should be changed when a joint of
different thickness is welded. The radii of electrodes
should also be varied according to the sheet thickness.
8.23 Mechanical Properties. A weldbonded joint

has much higher static and dynamic failure loading than
a resistance welded joint due to the adhesive bonded
area. Figure 31 shows a comparison of the failure load
between the uncured joint (spot weld), and the cured
joint as a function of the welding current. An increase of
88
S T D - A W S C L * L N / C L - L - E N G L 2000
= 07842b5
0533799 Tbb
AWS Cl.lMICl.l:2000
Table 57
Comparison between Resistance Spot Welding and Weld-Bonding of Aluminum
Alloys1**I
Spot Welding Weld Bonding
Surface Condition Existing Oxide Removed, Existing Oxide Removed
Oxide Deposited by Low-Voltage Anodizing
Low Contact Resistance
4 100
High Contact Resistance

800 micro-ohms
micro-ohms
8.9 kN (2000 Ib) Weld,
5.8 kN (1300 Ib) Weld,

13.3 kN (3000 Ib) Forge
17.8 kN (4000 Ib) Forge
54 O00 Amps
50 O00 Amps
Welding Time
7 Cycles
25 Cycles
Joint Strength
3.64.4 kN (800-1OOO Ib)
22.2 kN (5000 Ib)
Spot Spacing
25-38 m m (1-1.5 in.)
50-100 mm (2-4 in.)
Net Electrode Force

Weldine. Current
General Notes:
1. Alloys: 2024,7075,7475, 221.
2. Sheet thickness: 1.6 mm (0.063 in.).
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
3. Adhesive: modified epoxy.
the weld current increases the nugget size, which increases the weld strength. The failure load of the cured
weldbonded joint is higher than thatof the spot weld and
is not affected by the weld current. This is due to the fact
that the failure load of the adhesively bonded joint is
much stronger than that of the spot weld, because of the
larger area of bonding, and that the failure load represents the strengthof the adhesive bondedjoint rather than
the spot weld. As shown in Figure 32, the fatigue strength
of the weld bonded joint is almost as good as the adhesive bonded joint, although the former has stress risers at
the spot weld periphery.
Table 58
Typical Spot Welding Parameters' for
1.6 mm (0.063 in.) Thick 7075-T6
Aluminum Treated witha
Low-Voltage Anodizing Process
Electrode material
RWMA Class 1
Electrode (shank)
diameter
15.88 mm (0.625 in.)
Electrode tip radius
150 m m (6.0) in.
Net electrode force
8.9 kN (2000 Ib)
8.3 Other Metals. The weld bonding process can also be

used for other metals, such as steels and titanium alloys.
The advantage of increased joint strength from weld
bonding compared with resistance welding alone will be
reduced as the strength of the substrate increases. The
objectives of using weld bonding for steels and titanium
alloys are different from that for aluminum alloys. Weldbonding is not used for increasing joint strength but for
sealing out moisture from the faying surface, improving
acoustic damping ability, and for reducing vibration
(e.g., in hoods, doors, and deck lids in automobiles). The
surface treatment for conventional adhesive bonding of
steels and titanium alloys can be used for weld bonding
of these materials. Satisfactory results may be obtained
using conventional resistancewelding preweld treatments;
17.8 kN (4000 Ib)
Forge force
time
Upslope
3 cycles Forge delay

10 cycles from 15% to 40% heat
5 cyclesfrom 40% to 56% heat (48 kA)*
Welding time
2 cycles(at the peak)
Welding heat
56% (48 kA)
Downslope
3 cycles from 56% to 32% heat2

5 cycles from 32% to 20% heat
Hold time
200 cycles
General Notes:
1. A welding control capable of varying heat at each cycle is preferred.
2. Not a straight line.
89

STD=AWS C L * L M / C L * L - E N G L 2 O U O I07842b5 05L37V5 9T2

AWS C1.l M/CI .1:2000
15 O00
- - 3000
CUREDSTRENGTH
'
UNCUREDSTRENGTH
RECOMMENDED
CURRENT
WELDING
"
- - 2000
MINIMUM AVERAGE
"
(--.
MINIMUM
14.0
h
1000
"
/ 5E
ELECTRODE INDENTATION
"
MAXIMUM
12.0
10.0
--O
8.0
"
ADHESIVE:
MODIFIED EPOXY
35
40
OVERLAP 1 x 1 in.
-- N
6.0
W
4.0
WELDING CURRENT (KA)
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
Figure 31"Comparison of Tensile-Shear Strengthsof Uncured and Cured

(Single Spot) Weld-Bonded Joints of 7075T6 Aluminum Alloy
9. Equipment Monitoring and

Maintenance
however, the environment can affect the long term durability of the joint. In either case, conventional welding
schedules developed without adhesives will usually yield
acceptable weld quality. For some adhesives, an increase
in electrode force or a change in weld time, or both, may
be necessary.
Production of consistently acceptable, high quality resistance welds requires an effective machine maintenance program. The following is a listing of the
Resistance Welder Manufacturers' Association's recommended periodic inspection and service for resistance
welding equipment.I2 Additional information can be
found in the equipment manufacturer's manual.
8.4 Weld Bonding Quality and Mechanical Property

Tests. Various quality and mechanical property tests can
be performed on weld bondedjoints. In process monitoring, radiographic and ultrasonic inspections can be used
to determine the quality of the joint areas. The tests described in 4.9 for spot welds are applicable to spot welds
in weld bonded joints in the uncured condition, Fatigue
testing of weld bonded joints in aluminum alloys can be
performed using the test specimen shown in Figure 33.
12. Resistance WeUing Manual, 4th Edition, Resistance Welder

Manufacturers' Association, 1989. Published here by permission.
90

STD.AWS C L . L M / C L = L - E NGL 2000 m 07AV2b5 0 5 1 3 7 q b A37

AWS Cl.lM/C1.1:2000
TEMPERATURE = 75 i TF, HUMIDITY = 50 f 5% rh
(3500)
"
-- 15000
(3000)- (2500)- -
10000
"
(20W - (1500) --
(500)
"
(Ib-f) -- N
O
103
105
104
I
1
106
107
FATIGUE LIFE (CYCLES)
Figure 32"Comparison of Fatigue Test Resultsof Weld-Bonded and

Adhesive-Bonded Jointsof 7075T6 Aluminum Alloy
(3) After 10 to 15 minutes, turn off the water supply

to the weld contactor.
(4) Wipe all surfaces clean of dirt, dust, grease, oil,
and water.
Pay particular attention to cleaning clamp
surfaces.
Clean the machine and work area.
Dust lenses of anylight fixtures, windows and
doors, and transparent covers.
DAILY
At the start of each work shift, the following items
should be done:
(1) Turn on the air supply.
(2) Turn on the water supply.
(3) Check for water circulation.
(4) Check the air pressure setting.
(5) Lubricate the required points daily.
(6) Turn on power supplies.
(7) Check the settings on the weldcontrol.
(8) Dry cycle the equipment a few times to make sure
everything is functioning properly.
(9) Check all variables after a few welds, to see that
the water, air, machine settings, and contactors are working properly.
(10) Check the welds for desired quality.
At the end of each shift, the following items should be
done:
(1) Turn off the electrical supply.
(2) Turn off the air supply.
DAILY
(1) Cooling System
Checkforwater
leaks andmakenecessary
repairs.
(2) Electrical System and Control
Check for chattering relays or switches and
make necessary repairs.
Check timers and controls forproper dial settings according to the schedule chart.
Check for disabled interlocks or safety devices.
91

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
Other system checks are:
1.60 (0.063) SHEET

A
47.5 (1.87)
31.8 (1.25)
31.8 (1.25)
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
250 (10)
-<+L(FOR WELDBONDED
JOINT)
--
f
DOUBLER
3.18 (0.125)
SHEET
IN
NOTE: DIMENSIONS
mm (in.)
ARE SHOWN
GRIP DOUBLER
4.83 (0.150)
SHEET
Figure 33-Fatigue Test Specimen of Weld-Bonded and Adhesive-BondedJoints
Listen for noises indicating loose secondary connectors or broken leads.

Check for burned out bulbs and indicator lights,
enclosure lights, and other illumination features.
(3) Air System
Check for air leaks and repair.
Check line pressure and welding pressure.
Drain air line filters.
Check lubricator oil levels.
Feel solenoid valves for overheating-listen for
hum indicating improper seating of spool.
(4) Electrodes and Fixtures
Check lubrication of seam welding heads.
Check for discoloration on water-cooled components indicating improper cooling.
Check for pitted, worn, or dirty electrodes.
Check for groovesor markings of fixture.
Check electrode and fixture alignment.
( 5 ) Mechanical Equipment
Lubricate as prescribed.
If an automatic or centralized lubricating system

is used, checkfor insufficient or excessive amounts of lubricants and adjust as necessary.
Replace access covers.
Check for broken or loose components.
(6) Hydraulic System
Wipe top of reservoir.
Check for fluid leaks and make necessary repairs.
Check the reservoir for overheating.
Listen for unusual pump noises.
Check pressure gauge settings.
WEEKLY
Remove all oil spots from floor in walk areas.
Wash down floor in area of machine.
Check air and water leads.
If equipment has a standby mode, switchto standby
(no weld) and check machine operation. After determining satisfactory operation, return torun position. In addition, the following items should be done:
92


Check relays for evidence of wear or looseness.
(Never attempt to adjust relays as routine maintenance.
Contact tension and quick operation are preset and should
not require adjustment.)
Check programmable controls for unauthorized
changes in the program and correct before placing back
into operation.
Sequence machine
through
full manual
sequence.
Cleannameplates.
(2) Electrode and Fixtures
Make a thoroughinspection of electrodes and
electrode holders.
Clean electrode or fixture holders and clamps.
Check for misalignment and realign if necessary.
Check cylinder rod locking nuts.
Remove sample of oil from reservoir and test for
deterioration or contamination. (Testing interval will depend on fluid used and its age. Check fluid supplier for
recommendation.)
Check fluid filters.
(4)Air System
Check cylinder rod locking nuts.
Check cylinder mounting and tightenif necessary.
Check and clean out water traps and filters.
Checklinevoltagewithandwithoutmachine
load. Variation should not exceed 210 percent.
Remove vent filters (if any) and replace or clean.
Check insulation for cracks and dirt accumulation. Replace if necessary.
Clean all vacuum tubes, sockets, cables, printed
circuit boards and like equipment.
Check transformer leads for cracks or splits.
Check primary grounds.
(4)Air System
Remove air filter and clean.
Checkforloosecylinderbolts
or hold-down
plates.
Check shock blocks for secure weldments.
Check cylinders for air leaks and rods for score
marks.
Check for excessive sluggishness or sticking of
cylinder. Caution must be used when checking pneumatic
cylinders, since some spot or press welding heads will
descend if air pressure is removed.
Checkairgaugeforexcessivepressure
drops
during operation of welding electrode holders.
Checkallspeedcontrol
settings. Adjustand
lock.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
AWS Cl.lM/C1.1:2000
QUARTERLY
(1) General
MONTHLY:
Use master level and check machine. Re-level if
(1) General
necessary.
Make a special check for air leaks through valve
(2) Cooling System
seats and cylinder packing. Inspect all hoses for unusual
Checksystemthoroughlyandreplace
compowear and replace if required.
nents which show wear orcorrosion.
In addition, all relay and switch contacts should be in(3) Electrical System
spected for cleanliness and pitting. The contact surfaces
Polish all secondary contact surfaces to remove
should be cleaned as required. A thorough visual inspeccorrosion. Use an approved cleaning solvent. Some soltion of the entire machine, its controls and all accessories
vents are toxic and breathing the fumes can cause dizziness.
should be made for loose or missing parts. Replace or
Other solvents are flammable and require good ventilatighten as required.
tion; therefore, proper precautions should betaken. In the
(2) Cooling System
case of excessive corrosion, a fine abrasive should be
Reverse flush entire system to remove any accuused.
mulation of foreign matter. Verify volume of water flow.
Tighten all connections for good contact.
Remove and clean strainers and filters.
Check protective and overload devices.
Replace worn or cracked hoses.
(4)
Air
System
Tighten hose clamps.
Checkair gauges andregulatorswithpressure
Check water temperature and pressure.
indicator. Replace damaged regulators and gauges and
Check water shutoff solenoidsfor proper operation.
those that are sluggishor need calibration.
Check regulator diaphragms carefully.
Check control timing and power factor with oscilReplacewornorcracked
air hoseswith new
loscope or other appropriate equipment.If this equipment
hoses. Be sure connections are tight. High volume, high
is not available, contact your welding machine manufacpressure air hoses should receive special consideration.
turer and request assistance.
Poor hose connections may blow off and cause injury.
Check ground connections for good contact.
Tighten all terminal screw connections and visuClean or replace air-line mufflers, lubricators,
ally examine soldered connections.
and filters.
93

S T D - A W S CL=LM/CIIoL-ENGL 2000 W 078'42b5 05337'49 5'48 m

AWS Cl .1 M/C1.1:2000
(5) Manufacturer's
literature,
turer's Material Data Sheets

If recommended by oil supplier,replace oil in
reservoir with new oil.
Change or clean oil filters.
including Manufac-
10.2 Selection of Equipment. Select all resistance welding equipment for safe application to the work intended.
Give consideration to the personnel safety and health aspects of resistance welding whenchoosing equipment for
the work to be performed.
ANNUALLY
(1) General
A minor overhaul of the machine should be made
annually, probably during inventory shutdown or model
change-over. Remove all grease and rust from the machine and apply a coat of machinery paint.
Check for excessive wear of trunnions, bearings,
and brushes, and replace worn or damaged parts.
Check calibrationof timing and adjustif necessary.
(3) Air System
Replace air hoses where required. When replacing air hoses or piping, oil the inside witha smallamount
of light-weight oil.
Change oil if recommended or necessary.
( 5 ) Removing Equipment from Service
If a piece of resistance welding equipment is being removed from service for a period of time, the following
should be done to prevent unnecessary damage during
the idle time:
Drain and blow out water from all cooling lines,
especially:
-Weld controls, including either ignitron tubes
or SCR packages.
-Welding transformers.
-Electrode holders.
Drain hydraulic fluid,if used.
Protectallunpainted
surfaces fromrustand
corrosion.
Protecttheinsideandoutside
of cylindersfrom
rust.
Cover the equipment to prevent dirt accumulation.
Store equipment in a dry location.
1 0 3 Operator Training. Properly instruct workers designated to operate resistance welding equipment. Judge
their competency to operate their equipment.
Do not defeat nor otherwise disable safety devices such
as spark shields, guards, dual hand controls, or sensing
devices. Maintain vigilance for others entering a hazardous area and terminate machine operationuntil the area
is clear and the machineis safe to operate.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
10.4 Personal Protective Equipment.Employ personal

protective equipment suitable for the work being performed in the area of resistance welding equipment.
Such equipment includes protection for hearing, eyes,
face, head, and extremities. They include protective
clothing, respiratory devices, earplugs, footwear, helmets, and eye wear.
Additional discussions of this equipment can be found
in the following publications:
(1) ANSI 241 , Personal
Protection-f'rotective
Footwear
(2) ANSI 249.1, Safely in Welding, Cutting, and Allied Processes, published by AWS
(3) ANSI 287.1, Practice for Occupational and Educational Eye and FaceProtection
(4) ANSI 288.2,Respiratory Protection
(5) ANSI 289.1, Protective Headwear for Industrial
Workers
10.5 Installation. Install equipment in conformance with
NFPA 70, National Electrical Code, or its equivalent. Install the equipment with qualified personnel under the
direction of a technical supervisor. Prior to production use,
inspect the equipment and approve
it by competent safety
personnel to ensure that it is safe to operate.
10. Safety and Health
10.6 Guarding
10.1 General. This section is a limited noninclusive discussion of safety and health for resistance welding. Refer
to these documents for additional information:
(1) ANSI 249.1, Safety in Welding, Cutting, and Allied Processes, published by AWS
(2) The series EffectsonWeldingand
Health, published by AWS
(3) Safety and Health Facts, published by AWS
(4) OccupationalSafetyandHealthAdministration
(OSHA), Code of Federal Regulations, Title 29 Labor,
Chapter XVII, Part 1910, Occupational Safety and
Health Standards
10.6.1 Control Initiating Devices. Arrange or guard

initiating devices for portable and stationary resistance
welding equipment such aspush buttons, foot switches,
retraction, and dual-schedule switchesto prevent the operator from inadvertently activating them. Use suitable
initiating devices for automatic resistance welding machines that have detectiondevices interlocked in the initiating circuit to prevent injury to personnel.
10.6.2SparkShields.
Protectworkersfromthe
hazard of flying sparks by the installation of a guard of
suitable fire resistant material or the use of personal pro94


AWSCl.lM/C1.1:2000
tective eye wear and clothing, or both. The variations in

resistance welding operations are such that each installation shall be individually evaluated.
The primary intent is the protectionof all personnel in
the vicinity of the welding operation, including the operator. Further discussionof this topic can be foundin ANSI
249.1,Safety in Welding, Cutting, and Allied Processes,
published by the American Welding Society.
For flash welding equipment, provide flash guards of
suitable fire-resistant material control flying sparks and
molten metal.
placed on the movable holder,otherwise, provide guards.

If suitable guarding cannot be achieved, the use of twohanded control handles may be utilized. Locate these
handles and operating switches sufficiently remote from
the shear or pinch point to eliminate the possibility of
any finger or other body part entering the shear or pinch
point when the handsare on the controls.
10.6.5FlexibleAutomationResistanceWelding
Equipment
10.6.5.1 General. Robots and other flexible automation equipment to manipulate resistance welding guns
present additional hazards. Generally,this equipment is a
combination of portable and stationary resistance welding equipment. Protect flexible automation with guards,
latches, shields, barriers, and sensing devices.
10.63 Stationary Resistance Welding Equipment

10.63.1 General. Protect all chains, gears, operating linkages, and belts associated with welding equipment in accordance with ASME B15.1, Safety Standard
for Mechanical Power TransmissionApparatus.
10.6.5.2 Robots. Robots generally operate without

operator initiation and are frequently installed adjacent to
other robots and personnel. The robot arms can move
without warning. Prevent workersin the area from entering the working envelope of the robot. Contain the robot
within a fence or barricade that is electrically interlocked
to prevent unauthorized or unsafe access.
10.63.2 Single-RamandSingle-PointEquipment. On stationary single-ram welding machines, unless the workpiece size, configuration, or fixture
occupies both of the operators hands remotely from the
point of operation during the machine cycle, conduct operations in a manner that will prevent injury to the
operator. Employ one or more of the following features:
(1) Machine guards or fixtures that prevent the operators hands from passing under the pointof operation
( 2 ) Two-handed controls
(3) Latches
(4) Presence-sensing devices
( 5 ) Any similar device or mechanismthatprevents
operation of the ram while the operators hands or body
parts are within the point of operation
10.6.53 MobileResistanceWeldingAutomation. Other types of flexible automation may be mobile

and guided by sensors buried beneath the floor. Special
precautions are necessary for this equipment by not only
providing adequate signs and barriers but also on-board
devices to detect personnel and terminate movementuntil
personnel are at a safe distance.
10.7 Electrical
10.633 Multi-Gun
Equipment.
In multi-gun
welding machine operations, when any part of the operator can be expected to pass within the pointof operation,
stop the operations by the use of presence sensing devices, latches, blocks, barriers, or two-handed controls.
10.7.1Introduction. Electric shock from welding

equipment can kill and cause severe burns. To avoid electric shocks:
(1) Read the instruction manual before installing, operating, or servicing the equipment.
( 2 ) Haveall installation, operation, maintenance, an
repair work performed onlyby qualified people.
(3) Properly install and ground theequipment according to the instruction manual and national, state, and
local codes.
(4) Do not touch live electrical parts.
(5) Useonlywellmaintained
equipment. Repair or
replace damaged parts beforefurther use.
10.6.4 Portable Resistance Welding Equipment

10.6.4.1SupportSystemSafety.
Equipall suspended portable welding gun equipment, with the exception of the gun assembly, with a redundant support
system capable of supporting the total impact load in the
event of failure of any component of the primary supporting system. Design the systemto be fail safe. The use
of devices such as cables, chains, and clamps is considered satisfactory.
10.7.2 Voltage. Limit all external weld-initiating control circuits to a maximum voltage of 120 volts rms for
stationary equipment, as determined by the National
Electrical Manufacturers Association (NEMA) and
adopted by OSHA.
10.6.4.2 Moving Holder.The moving holder onan

RW weld gun is activated by a power device, usually a
cylinder. Normally, one holder is dynamic, but guns are
also available in which both holders can be activated
through a mechanical linkage. Design the moving holder
mechanism to prevent pinch or shear points to fingers
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

10.73 Capacitors. Give suitable insulation and protection by complete enclosureto resistance welding equipment
95
S T D - A W S C L * L M / C L = L - E N G L 2000 B 078'!2b5 0533753 %Tb

AWS Cl .1M/Cl.l:2OOO
and control panels containingcapacitors used for stored

energy resistance welding involving high voltages (over
550 volts rms). Keep the door and panels locked except
during maintenance. Provide all enclosure doors with
suitable interlocks and contacts wired into the control
circuit. Design such interlocks or contacts so as to effectively interrupt power and short
circuit all capacitors when
the panel dooris opened. Install a manually operated switch
or suitable device in addition to the mechanical interlocks or contacts, as an added safety measure for assuring complete dischargeof all high voltage capacitors.
The panel box itself is considered an enclosure and
capacitors located inside such a panel box do not need
further enclosure when the other requirements of this
section are met.
currents to flow between transformers when multi-phase

primary supplies or different secondary voltages,or both,
are used for the several guns. A similar condition can
also exist with portable spot welding machines, when
several units are used on the same fixture or assembly, or
on one that is nearby. Such situations may require use of
a grounding reactor or isolation contactor.
10.8 Static Safety Devices. On large welding machines

incorporating a platen, provide electrically interlocked
safety devices such as pins, blocks, or latches to block
any movement of the platen or head. The intent is to require the use of these devices when the machine area is
so large that maintenance or setup would require the insertion of more than hands into theclosure area. The device causes the energizing circuit to be broken and
mechanically prevent movement of the platen or head
under static load. More than one devicemay be required,
varying with machinesize or accessibility, but makeeach
device capable of sustaining the full static load involved.
10.7.4 Locks and Interlocks

10.73.1 Doors. Keep doors and access panels of
all resistance welding machines and control panels
locked or interlocked to prevent access by unauthorized
persons to electrically live portions of the equipment.
Keep doors or accesspanels locked if keys, wrenches, or
other instruments are required to open them. Follow
lockout out procedures asrequired be OSHA.
10.9 Ventilation.Resistance weldingoperations can produce fumes and airborne particulates from the materials
being welded as well as from the composition of the
electrodes. Provide suitable ventilation to removesmoke,
fumes, and airborne contaminants. Adequateventilation
means enough ventilation such that personnel exposure
to hazardous concentrationsof airborne contaminants is
maintained below the allowable levelsspecified in Occupational Safety and Health Administration (OSHA),
Code of Federal Regulations, Title 29 Labor, Chapter
XVII, Part 1910, Occupational Safety and Health Stand a r d ~ . Particular
'~
attention shall be paid when electrodes and metals being welded contain hazardous
chemicals.
10.7.5 Stop Buttons. Provide one or more emergency

stop buttons on all resistance welding equipment that
have the following characteristics:
(1) Require three or more seconds to complete a sequence.
(2) Have mechanical movements that can be hazardous if guards are removed.
(3) Installationanduseofemergency
stop buttons
will not i n themselves create additional hazards to
persons.
In the above context, sequence means the action and
time required by the machine from the time the run buttons are locked in (interlocked) and can be released,until
the machine stops of its own accord.
10.10 Maintenance. Good housekeeping is essential for

safety in resistance welding. Equipment and welding
areas shall be kept in good, clean condition. Periodic inspections shall be conducted and recorded by qualified
personnel.
Necessary repairs shall be madeby authorized personnel. The operators or maintenance personnel shall report
any equipment defects to supervisory personnel. Use of
an unsafe machine shall be discontinued until safety repairs are completed.
Never leave tools or parts in the area of the secondary
winding of a resistance welding machine. Resistance
welding secondary circuits develop a strong magnetic
field when energized for welding. The force of this magnetic field can forcefully propelmetallic items which can
cause injury.
10.7.6 Grounding.The primary windingof a welding

transformer may become shortedto the secondary winding, creating a potential hazard to workers that
may come
in contact with the secondary. Ground the welding transformer secondary by one of the methods below or provide equivalent protection as in (3) below:
(1) Permanent grounding of the welding secondary
circuit.
(2)Connecting a grounding reactor across the secondary winding with reactor tap@) toground.
(3) As an alternative, on non-portable machines,
installing an isolation contactor to open both sides of the
line to the primaryof the welding transformer.
The groundingof one side of the secondary windings
on multi-spot machines cancause undesirable circulating
13. Available from Superintendentof Documents, U.S. Government Printing Office, Washington, DC 20402.
96
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AWS Cl .1 MlCl.1:2000
10.13 Lighting. Adequate lighting shall be provided to

promote operator safety. This can be done by relocating
building lighting or by providing lighting fixtures around
the machine withsuitable lenses.
Pneumatic and hydraulic connections and lines shall

be periodically checked to prevent leaks. Compressed air
is generally pressurized to approximately 100 psi (0.7
MPa) and can propel hazardousobjects if a line fails.Hydraulic fluids are even more hazardous since they normally operate at 700 psi (4.8 MPa) or above. In addition,
spilled hydraulic fluids can cause slip hazards.
10.14 Signs. Post suitable precautions so that operators

are reminded of the hazards in the workplace. The signs
shall be in accordance with ANSI 2535.5, Accident Prevention Tags.
10.11 Fire Hazards. Resistance welding causessparks,

molten metal from expulsion,an hot surfaces. Sparks and
resistance welding expulsion can cause fire. All combustibles shall be removed or be properly shielded against
ignition. Maintain suitable fire extinguishers at the site.
For more information see NFPA Standard 51B,Cutting
and Welding Processes.
10.15 Hazardous Materials

10.15.1AlkalineSolutions.
Useprecautionwhen
handling alkaline (caustic) solutions. They can cause
chemical burns and violent chemical reactions can result
when mixed with acids. Before use, read and understand
the manufacturers instructions, Material Safety Data Sheets
(MSDSs), and your employers safety practices.
10.12 Noise. Resistance welding equipment produces

noise from the exhaust of pneumatic devices, large motors used to operate the machines, hydraulic units and the
welding current. Excessive noise is a know health hazard. The overexposure to noise can cause loss of hearing
that is either full or partial.
Noise emissions may be controlled with one or a combination of the following:
(1) Reduce the intensity of the source
(2) Shield the source where practical
(3) Mufflers
(4) Exhaust manifolds
(5) Sound deadening enclosure
(6) Sound deflectors
If engineering methods fail to reduce noise to acceptable levels, wear approved personal protective device
such as ear muffs or ear plugs appropriate for the situation. which require a Hearing Conservation Program if
noise levels reach 85 dB on an 8-hour, Time Weighted
Average (TWA) basis. If noise level is questionable, have
a certified safety specialist or Industrial Hygienist take
measurements and make recommendations.
10.15.2 Acids Including Picking Acid.

Pickling acid,
hydrofluoric acid and nitric acid are hazardous to the
skin and eyes. Hazardous fumes can be produced by
these acids and violent chemical reactions can result
when acids are mixed with other chemicals, especially
those with basic pHs. Acids can also eat through some
clothing. Use precautions when working near or with acids. Strict precautions are necessary in their use and disposal. Acids should be added to water, not water into
acid. Pickling, hydrofluoric andnitric acids cause chemical burn to the skin. Mix and use pickling acid in a properly vented area. Rinse the surfaces in clean water and
dry them after pickling. Before use, read and understand
the manufacturers instructions, Material Safety Data
Sheets (MSDSs), and your employers safetypractices.
10.153 Solvents. Some solvents are toxic and breathing the fumes can cause dizziness. Other solvents are
flammable and require good ventilation; therefore,
proper precautions should be taken. Before use, read and
understand the manufacturers instructions, Material
Safety DataSheets (MSDSs), and your employers safety
practices.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
97


AWS C l .1 M/C1.1:2000
Table 59
Commonly Used Metric Conversions
Inch-Millimeter Conversion
To convert inches to millimeters, multiply the inch value by 25.4
Inch and Millimeter Decimal Equivalents of Fractions of an Inch
Fraction
1/64
1/32
3/64
1/16
5/64
3/32
7/64
118
9/64
5/32
11/64
3116
13/64
7/32
15/64
114
17/64
9/32
1 9/64
5116
21164
1 1/32
23/64
318
25/64
13/32
27/64
7/16
29/64
15/32
31/64
1 /2
Decimal
Millimeter
0.015
0.031
0.046
0.062
0.078
0.093
0.109
0.125
0.140
0.156
0.171
O. 187
0.203
0.218
0.234
0.250
0.265
0.281
0.296
0.312
0.328
0.343
0.359
0.375
0.390
0.406
0.421
0.437
0.453
0.468
0.484
0.500
0.396
0.793
1.190
1.587
1 .Y84
2.38 1
2.778
3.175
3.571
3.968
4.365
4.762
5.159
5.556
5.953
6.350
6.746
7.143
7.540
7.937
8.334
8.73 1
9.128
9.525
9.921
10.318
10.715
11.112
1 so9
1
11.906
12.303
12.700
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

T-
Inch
Inch
Fraction
33/64
17/32
35/64
9116
37/64
19/32
39/64
518
4 1/64
21/32
43/64
11/16
45/64
23/32
47/64
314
49/64
25/32
5 1/64
13/16
53/64
27/32
55/64
718
57/64
29/32
59/64
15/16
61/64
3 1 132
63/64
1
Decimal
0.5 15
0.531
0.546
0.562
0.578
0.593
0.609
0.625
0.640
0.656
0.671
0.687
0.703
0.718
0.734
0.750
0.765
0.781
0.796
0.812
0.828
0.843
0.859
0.875
0.8YO
0.906
0.921
0.937
0.953
0.968
0.984
1.o00
Millimeter
13.0%
13.493
13.890
14.287
14.684
15.081
15.478
15.875
16.271
16.668
17.065
17.462
17.859
18 256
18.653
19.050
19.446
1 9 .843
20.240
20.637
21.O34
21.431
21.828
22.225
22.621
23.018
23.415
23.812
24.209
24.606
25.003
25.400
98
S T D - A W S C L D L M / C L * L - E N G L 2000
0 7 8 4 2 b 5 05L375q 905
AWS Cl .1 M/C1.1:2000
RESISTANCEWELDING DATA SHEET

EQUIPMENT IDENTIFICATION
TYPE
SERIAL
TRANSFORMER
RATING
NO.
CONTROL
SPOT
SIDE
A
SIDE
I Thickness
Veld Current
I
i.C. Current
Approx. Analysis (type)
Phase
D andlor
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
-1
PROJECTION
Settina
I
I
I
Surface Cond.
Ultimate
Strength
ion-synchronous timing
Yield Strength
Elongation %
Red. in Area%
Squeeze Time
Hardness
2001 Time
Material
i o l d Time
I
I
I
Shape
Uo. of Pulsations
Electrode Force
Squeeze Force
Forging Force
Tension Shear Test
Tension Test
Diameter
I"
Overlap or Flange
v)
Spacing
Degree Twist at Ult.
Indentation
Nugget Size
I"D-I
Other Tests:
I Number
I Location
Photos
Remarks:
Figure 34-Form
for Resistance Welding Data Sheet for Spot and Projection Welding
99


RESISTANCE WELDING DATASHEET

EQUIPMENT IDENTIFICATION
TYPE
TRANSFORMER
RATING
NO.
W
SEAM
CONTROL
SIDE
IThickness
SIDE
A
Weld Current
S. C. Current
Approx. Analysis (type)
Tap and/or Phase Settina

Throat Opening
-I
$
W
Surface Cond.
Throat Spacing
Ultimate Strength
Synchronous or
Non-synchronous Timing
Yield Strenath
Elongation %
Heat Time
Red. in Area %
Cool Time
Hardness
Electrode Force
I Material
Tension Shear Test
Shape
Tension Test
B
6
I Yield Point
YW
TORSIONAL
I
z
VJ
5c
5
-1
Mod. of Rupt.
Ultimate
I Degree Twist at Ult.
Indentation
Roll Spead mm per min. (in. per min.)

Spots per mm (in.)
Other Tests:
Width of Weld
Overlap or Filler
Length of Weld
Remarks:
Photos
Figure 35-Form for Resistance Welding Data Sheetfor Seam Welding

--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---

1O0
RESISTANCE WELDING DATA SHEET

MACHINE DESCRIPTION
SIDE A
SIDE B
MFGR.
SERIAL
FINAL
FLASHING
INITIAL
FLASHING
PREHEAT
UPSET
POSTHEAT
Time
Voltage (Open Circuit)
Distance at
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
kVA
Force
I Current
l 1
COMMENTS
PLATEN TRAVEL INFORMATION

TESTING METHODS
REMARKS:
Tension
U Bend Test
Hardness
Macro
Figure 36-Form
for ResistanceWelding Data Sheet for Flashor Upset Welding

101


Annex A
Guidelines for Preparationof Technical Inquiries for
AWS Technical Committees
(Nonmandatory Information)
(This Annex is not a part ofAWS C1.1 M/C1.1:2000,Recommended Practices for Resistance Welding, but is included
for information purposes only.)
The AWSBoardofDirectorshasadoptedapolicy
whereby all official interpretations of AWS standards
will be handled in aformal manner, Under that policy, all
interpretations are made by the committee that is responsible for the standard. Official communication concerning an interpretation is through the AWS staff member
who works with that committee. The policy requires that
all requests for an interpretation be submitted in writing.
Such requests will be handled as expeditiously as possible but due to the complexity of the work and the procedures that must be followed, some interpretations may
require considerable time.
A2.1 Scope. Each inquiry must address one single provision of the Standard, unless the point of the inquiry involves two or more interrelated provisions. That provision
must be identified in the Scope of the inquiry, along with
the edition of the standard that containsthe provisions or
that the Inquirer is addressing.
A2.2 Purpose of the Inquiry.The purpose of the inquiry

must be stated in this portion of the inquiry. The purpose
can be either to obtain an interpretation of a Standard requirement, or to request the revisionof a particular provision in the Standard.
A2.3 Content of the Inquiry. The inquiry should be
concise, yet complete, to enable the committee to quickly
and fully understand the point of the inquiry. Sketches
should be used when appropriate and all paragraphs, figures, and tables (or the Annex), which bear on the inquiry must be cited.If the point of the inquiry is to obtain
a revision of the Standard, the inquiry must provide technical justification for that revision.
A2.Procedure
All inquiries must be directed to:
Managing Director, TechnicalServices
550 N.W. LeJeune Road
Miami, FL 33126
A2.4 Proposed Reply. The inquirer should, as a proposed reply, state an interpretation of the provision that is
the point of the inquiry, or the wording for a proposed
revision, if that is what inquirer seeks.
All inquiries must contain the name, address, and afinfiliation of the inquirer, and they must provide enough
formation for the committee to fully understand the point
of concern in the inquiry. Where that point is not clearly
defined, the inquiry will be returned for clarification. For
efficient handling, all inquiries should be typewritten and
should also be in the format used here.
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
Al. Introduction
A3. Interpretation of Provisions of the

Standard
Interpretations of provisions of the Standard are made
by the relevant AWS Technical Committee.The secretary
103


Previous page is blank
of the committee refers all inquiries to the chairman of

the particular subcommittee that hasjurisdiction over the
portion of the Standard addressed by the inquiry. The
subcommittee reviews the inquiry andthe proposed reply
to determine what the response to the inquiry should be.
Following the subcommittees development of the response, the inquiry and the response are presented to the
entire committee for review and approval. Upon approval
by the committee, the interpretation will bean official interpretation of the Society, and the secretary will transmit
the response to the inquirer and to the Welding Journal
for publication.
Standard. The Board of Directors Policyrequires that all

AWS Staff members respond to a telephone request for
an official interpretation of any AWS Standard with the
information that such an interpretation can be obtained
only through a written request. The Headquarters Staff
can not provideconsulting services.The staff can, however,
refer a caller to any of thoseconsultants whose names are
on file at AWS Headquarters.
A6. The AWS Technical Committee

The activities of AWS Technical Committees in regard to interpretations, are limited strictly to the Interpretation of provisions of Standards prepared by the
Committee or to consideration of revisions to existing
provisions on the basis of new data or technology. Neither the committee nor the Staff is in a position to offer
interpretive or consulting services on: (1) specific engineering problems, or(2) requirements of Standards applied to fabricationsoutside the scope of thedocument or
points not specifically covered by the Standard. In such
cases, the inquirer should seek assistance from a competent engineer experiencedin the particular field of interest.
A4. Publication of Interpretations

All official interpretations will appear in the Welding
Journal.
A5. Telephone Inquiries

Telephone inquiries to AWS Headquarters concerning
AWS Standards shouldbe limited to questions of a general nature or to matters directly related to the use of the
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
104

AWS List of Documents on Resistance Welding

The followingis a list of documents prepared by the Cl Committee on resistance Welding:
AWS Designation
~
~~
Cl.lM/Cl.l
Recommended Practices for Resistance Welding
c1.2
Recommended Practices for Spot Welding Aluminum and Aluminum Alloys
C1.3
Recommended Practices for Resistance Welding CoatedLow Carbon Steels
C1.4M/C1.4SpecificationforResistanceWelding
-~
~~
~~~
Steels
The Professionals Advisor on Resistance Welding
PARW
~
of CarbonandLow-Alloy
~~
--``````,``,```,,```,,,```,`,-`-`,,`,,`,`,,`---
For ordering information, contact the AWS Order Department, American Welding Society, 550 N.W. LeJeune Road,
Miami, FL 33126. Telephones:(800) 334-9353, (305) 443-9353, ext. 280;FAX (305) 443-7559.
105


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AWS Cl .1M E 1.

An American National Standard

Copyright American Welding Society

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

Resistance weld, spot weld, seam weld,

for Resistance Welding

American Welding Society

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

Statement on Useof AWS American National Standards

Copyright American Welding Society

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

Centerline Welding, Limited

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

AWS C l Committee on Resistance Welding

by the AWS Committee on Resistance

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

Personnel .................................................................................................................................................................... 111

2. Referenced Documents ......................................................................................................................................... 1

5 . Projection Welding ..............................................................................................................................................

Weld Bonding ...................................................................................................................................................... 87

Copyright American Welding Society

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

9. Equipment Monitoring and Maintenance............................................................................................................

10. Safety and Health ................................................................................................................................................

AWS List of Documents on Resistance welding........................................................................................................ 105

Copyright American Welding Society

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

Spot Welding Parameters for Annealed Nickel

Spot Welding Parameters for Nickel-Iron-Chromium AlloyX ...................................................................

Seam Welding Parameters for Nickel-Iron-Chromium Alloy X ..................................................................

Copyright American Welding Society

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

STDOAWS C L * L M / C L * L - E N G L 2000 D 078Y2b5 0 5 L 3 b 5 b 8T7

I t is the intent of this publication to present current

1 . Available from AA, 900 19th Street, NW, Washington, DC

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

(12) Society of Manufacturing Engineers, Tooland

bake-hardenable steel. Low-carbon steel having the

2.1 Safety References

dent-resistant steel. A general term for low-carbon

high-strength low-alloy (HSLA) steel. A general term

4. Resistance Spot and Seam Welding

5. Available from SME, One SME Drive, PO Box 930, Dear-

Copyright American Welding Society

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

3. Nonstandard Terms and

governing metal thickness. The thickness of the sheet

STD=AWS CL*LM/CL.L-ENGL 2000 m . 0 7 8 9 2 b 5 0 5 L 3 b 5 8 b7T

4.13 Welding Parameters. The data shown in Tables

4.1.13 High-CarbonSteels. High-carbon steels

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

4.1.1.4 High-StrengthLow-Alloy (HSL4) Steels.

STD-AWS CL.LM/CL-L-ENGL 2000

078q2b5 0513b59 50b

0.51 (0.020) 4.76 (0.187) 1.78 (400)

4.13.2 Net Electrode Force. High-strength (HS)

and low-alloy steels. Some HS steels require very short

4.13.4 Temper Time. Medium-carbon and some

4.133 Hold Time. Typical hold time to solidify

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004

078112b5 0513bb0 228

Document provided by IHS Licensee=Honeywell Phoenix/6112045100, 09/07/2004