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Tool - Resistance Welding Troubleshooting Guide

The document provides troubleshooting instructions for resolving welding issues. It lists common symptoms and problems and identifies the most likely causes based on priority. It instructs the user to start with the highest priority potential cause and methodically work through lower priorities if needed. It emphasizes consistent process control and making one adjustment at a time using a scientific method.

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vladimirsoler01
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221 views

Tool - Resistance Welding Troubleshooting Guide

The document provides troubleshooting instructions for resolving welding issues. It lists common symptoms and problems and identifies the most likely causes based on priority. It instructs the user to start with the highest priority potential cause and methodically work through lower priorities if needed. It emphasizes consistent process control and making one adjustment at a time using a scientific method.

Uploaded by

vladimirsoler01
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
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Insufficient

Overheating of Weldment Discoloration Weak Weld Nugget Metal Expulsion Sparking

60
INSTRUCTIONS:
CAUSE
Push the buttons for the SYMPTOM OR PROBLEM. Determine most likely CAUSE
and SOLUTION based on PRIORITY numbers with 1 as highest priority. Start Excess Current/Energy
troubleshooting with 1 and then proceed to 2 and so on. In cases where there are
multiple causes with the same priority, use the following sequence for Insufficient Current/Enery
troubleshooting: MATERIAL RELATED, ELECTRODE RELATED, WELDHEAD POWER SUPPLY Excess Time
RELATED, POWER SUPPLY RELATED. RELATED
Insufficient Time
Insufficient Squeeze Time
Insufficient Hold Time
BASIC TROUBLESHOOTING RULES: (In order of Priority) Insufficient Upslope
Verify correct equipment set-up and line voltage; insure all cable and other electrical Excess Force
connections are tight; replace broken flexures. WELDHEAD Insufficient Force
RELATED Poor Weldhead Follow-up
Use clean electrodes and materials. Insure electrode alignment with faces parallel to Wrong Polarity
each other and perpendicular with surface of parts to be welded. Poor Projection Design
Exercise consistent process control over materials, equipment and the weld process. MATERIAL
RELATED Poor Plating of or Oxidized Dirty Parts
Incompatible Metals
Dress electrodes regularly and consistantly using 600 grit paper or polishing disk (no Requires Cover Gas
files). Parts Mis-positioned
As a general starting point, use shortest time, highest reasonable force and a ELECTRODE Wrong Electrode Material
weldhead with fast follow-up and low mass electrode holders. RELATED Dirty Electrodes
Electrode Tip Shape
Follow instructions above to determine best course of action. Mushroomed Electrodes

Try simplest solutions/adjustments first.

Change only one variable at a time.


If one variable does not resolve the problem, return it to its starting setting and try a
second variable and then a third before changing two variables at once. Follow the
scientific process of a controlled experiment.

If further assistance is needed, contact your local Unitek Equipment Sales


Representative or call the Factory Applications Lab at (626) 303-5676 for assistance.
Inconsistent Electrode
Welds Electrode Damage Sticking

PRIORITY SOLUTIONS

3 Decrease current in steps of 5-10%

0 Increase current in steps of 5-10%


1 Decrease weld time in steps of 5-10% (N/A for CD)
0 Increase weld time in steps of 5-10% (N/A for CD)
0 Increase squeeze time in steps of 20 milliseconds (1 cycle for AC)
2 Increase hold time in steps of 20 milliseconds (1 cycle for AC)
2 Increase upslope time in steps of 5 milliseconds (N/A for CD and AC)
0 Decrease force in steps of 10-20%
2 Increase force in steps of 10-20%
3 Use weldhead with fast follow-up and/or reduce mass of top electrode holder.
0 Reverse polarity of each electrode
0 Contact Unitek Equipment Applications Lab for assistance

3 Clean parts before welding. Check plating thickness and compatibility.


0 Change one metal or use third interface metal
1 Use argon or similar cover gas.
0 Provide tooling/fixtures to hold parts in place.
1 Check Electrode/Material Selection Guide.
4 Clean electrodes and/or parts to be welded.
4 Use constant area electrodes or shape to suit application.
0 Replace or reshape electrodes or increase cleaning schedule.

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