Resistant Welding

Description

RESISTANCE WELDING TRAINING PROGRAM FOR AIDT

 

DAY 1:

CLASSROOM – 8 hours of Instruction

• Class Objectives
• Types of Resistance Welding and Welders
  • Spot
  • Multi-spot
  • Press / Projection
  • Seam
  • Flash and Upset Butt
• Resistance Welding Theory
  • Force, Current, Time, Temperature
  • Resistance Welding Objective
  • Resistance in Welding Circuit
  • 10 Most Common Variables
• Quiz
• Force
  • Force, Current, Time
  • Introduction to Welding Charts
  • Understanding Expulsion
  • Importance of Squeeze Time
• Current
  • Joules Law
  • Overview of Transformer
  • Current Squared – I²
  • Impedance / Inductive Reactance

• Weld Time
  • Explanation
  • Weld Schedule Considerations
• Hold Time
  • Explanation
  • Video of actual Weld Nugget Formation
• Weld Controls
  • Contactors
  • Basic Wiring
  • Control Settings
  • Squeeze Time
  • Weld Time
  • Percent Current / Constant Current
  • Current Adjustments
  • SCR
• Diagrams and Charts
  • % Current Comparison
  • Current and Force
  • Hold Time
  • Off Time
  • Slope
  • Impulses
  • Quench / Temper
  • Correct Timing Functions
  • Working with Weld Charts
• Temperature
  • Water Cooling
• Electrodes
  • Explanation
  • Materials
  • Shapes
  • Tips / Faces
  • Electrode Classes
  • Electrode Notes to Consider

• Welder Set-up
  • Set-up Priority
    • Electrode Choice
    • Force Determination
  • Weld Monitors
  • Weld Attempts
  • Continuing with the Process
  • Adjustment of Hold Time
  • Adjustment of Squeeze Time
  • Weld Window / Weld Lobes
• Weld Quality
  • Connections
  • Surface Conditions
  • Difficult Cases
  • Different Thicknesses
  • Coated Material
  • Edge Welds
  • Weld Spacing / Shunting
• Quality Assurance
  • Testing Welds
  • Typical Problems
    • Expulsion
    • Cold Welds
  • Safety in Resistance Welding
    • Safety Hazards
    • How to Avoid Hazards
    • Quiz
    • LOTO
  • Quiz

18.0 Questions / Discussion

 

RESISTANCE WELDING TRAINING PROGRAM FOR AIDT

 

DAY 2:

SHOP – 2 hours on Shop Floor

• Welder Review/Discussion

 

CLASSROOM – 6 hours of Instruction

• Class Objectives
• Current
  • Joules Law of Heating
  • Transformer Theory
  • Transformer Construction
    • Package Style
    • Machine Style
  • Tap Switch
  • Turns Ratio
  • Keeping the Balance
  • Effects of I²
• Inductive Reactance
  • Resistive Losses in Secondary Circuit
  • Real Life Inductance
• DC Equipment
  • MFDC System
• Quiz
• KVA
  • Explanation
  • Duty Cycle
• Force System Components
  • Electrode Choice
  • Force System Choices
    • Air Pressure System
      • Components
        • Air Filter
        • Air Pressure Regulator
        • Air System Lubricator
        • Solenoid Valves
        • Flow Control Valves
        • Air Cylinder
        • Single Piston Air Operation
        • Servo Gun Technology

• Quiz
• Quiz
• Weld Controls
  • Types
  • Settings
• Quiz
• Temperature / Water Cooling
  • Water Circuits
  • Water Quality Recommendations
  • Cooling Requirements – IGBT / MFDC

DAY 3:

 

• CLASSROOM – 2 hours
  • Spot Welding Discussion

• SHOP – 2 hours
  • Spot Welding Practice

• CLASSROOM – 2 hours
  • Projection Welding Discussion

• SHOP – 2 hours
  • Projection Welding Practice

DAY 4:

• CLASSROOM – 2 hours
  • Maintenance Troubleshooting

• SHOP – 4 hours
  • Hands-on Maintenance Troubleshooting

• CLASSROOM – 1 hour
  • Resistance Weld Testing

• SHOP – 1 hour
  • Hands-on Resistance Weld Testing