Resistant Welding

Categories
Course 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

 

 

 

 

 

 

 

 

 

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
  • Course Length
    32 hours
  • Min Attendee
    2 per company per class
  • Max Attendee
    6 max class size
  • Pass/Fail Required?
    Yes
  • Certification Offered?
    Yes