Applications

Spot welding is typically used when welding particular types of sheet metal. Thicker stock is more difficult to spot weld because the heat flows into the surrounding metal more easily. Spot welding can be easily identified on many sheet ■metal goods, such as metal buckets. Aluminum alloys can also be spot welded. However, their much higher thermal conductivity and electrical conductivity mean that up to three times higher welding currents are needed. This requires larger, more powerful, and more expensive welding transformers. Perhaps the most common application of spot welding is in the automobile manufacturing industry, where it is used almost universally to weld the sheet metal to form a car.

Заведующий кафедрой

общеобразовательных дисциплин

____________ В.П. Павлов

Уфимский государственный Кафедра общеобразовательных

авиационный технический дисциплин

университет

ЭКЗАМЕНАЦИОННЫЙ БИЛЕТ № 7

Факультет: АТС (СП) Вопрос: 1

Electrical notes

The basic spot welder consists of a power supply, an energy storage unit (e.g., a capacitor bank), a switch, a welding transformer, and the welding electrodes. The energy storage element allows the welder to deliver high instantaneous power levels. If the power demands are not high, then the energy storage element isn't needed. The switch causes the stored energy to be dumped into the welding transformer. The welding transformer steps down the voltage and steps up the current. An important feature of the transformer is it reduces the current level that the switch must handle. The welding electrodes are part of the transformer's secondary circuit. There is also a control box that manages the switch and may monitor the welding electrode voltage or current.

The resistance presented to the welder is complicated. There is the resistance of secondary winding, the cables, and the welding electrodes. There is also the contact resistance between the welding electrodes and the workpiece. There is the resistance of the workpieces, and the contact resistance between the workpieces.

At the beginning of the weld, the contact resistances are usually high, so most of the initial energy will be dissipated there. That heat and the clamping force will soften and smooth out the material at the electrode-material interface and make better contact (that is, lower the contact resistance). Consequently, more electrical energy will go into the workpiece and the junction resistance of the two workpieces. As electrical energy is delivered to the weld and causes the temperature to rise, the electrodes and the workpiece are conducting that heat away. The goal is to apply enough energy so that a portion of material within the spot melts without having the entire spot melt. The perimeter of the spot will conduct away a lot of heat and keep the perimeter at a lower temperature. The interior of the spot has less heat conducted away, so it melts first. If the welding current is applied too long, the entire spot melts, the material runs out or otherwise fails, and the "weld" becomes a hole.

The voltage needed for welding depends on the resistance of the material to be welded, the sheet thickness and desired size of the nugget. When welding a common combination like 1.0 + 1.0 mm sheet steel, the voltage between the electrodes is only about 1.5 V at the start of the weld but can fall as low as 1 V at the end of the weld. This decrease in voltage results from the reduction in resistance caused by the workpiece melting. The open circuit voltage from the transformer is higher than this, typically in the 5-10 V range, but there is a large voltage drop in the electrodes and secondary side of the transformer when the circuit is closed.

Заведующий кафедрой

общеобразовательных дисциплин

____________ В.П. Павлов

Уфимский государственный Кафедра общеобразовательных

авиационный технический дисциплин

университет

ЭКЗАМЕНАЦИОННЫЙ БИЛЕТ № 7

Факультет: АТС (СП) Вопрос: 2

Welder

A welder (also weldor, which term distinguishes the tradesman from the equipment used to make welds) is a tradesman who specialises in welding materials together. The materials to be joined can be metals (such as steel, aluminum, brass, stainless steel etc.) or varieties of plastic or polymer. Welders typically have to have good dexterity and attention to detail, as well as some technical knowledge about the materials being joined and best practices in the field.

Safety issues

Welding, without the proper precautions appropriate for the process, can be a dangerous and unhealthy practice. However, with the use of new technology and proper protection, the risks of injury and death associated with welding can be greatl; reduced. Because many common welding procedures involve an open electric arc or flame, the risk of burns is significant. To prevent them, welders wear personal protective equipment in the form of heavy leather gloves and protective long sleeve jackets to avoid exposure to extreme heat and flames. Additionally, the brightness of the weld area leads to a condition called arc eye in which ultraviolet light causes the inflammation of the cornea and can burn the retinas of the eyes. Goggles and welding ' helmets with dark face plates are worn to prevent this exposure, and in recent years, new helmet models have been produced that feature a face plate that self-darkens upon exposure to high amounts of UV light. To protect bystanders, opaque welding curtains often surround the welding area. These curtains, made of a polyvinyl chlorid plastic film, shield nearby workers from exposure to the UV light from the electric ai but should not be used to replace the filter glass used in helmets. Welders are also often exposed to dangerous gases and particulate matter.

Заведующий кафедрой

общеобразовательных дисциплин

____________ В.П. Павлов

Уфимский государственный Кафедра общеобразовательных

авиационный технический дисциплин

университет

ЭКЗАМЕНАЦИОННЫЙ БИЛЕТ № 8

Факультет: АТС (СП) Вопрос: 1