175-4591 datasheet(50/54 Pages) ETC2

50 / 54 page

Thickness Electrode

Net

Weld

Welding

Mini-

Dia-

Thickness

“T” of

Diameter

Elec-

Time

Current

mum

meter

Minimum Shear

“T” of

Thinnest

trode

(Single (Approx.)

Con-

Weld

Strength

Thinnest

Outside

Force

Im-

tacting

Spacing

Fused

Piece

pulse)

Over-

Zone

lap

Lbs.

Tensile

Strength Strength

Cycles

Below

70000

(60

70000

PSI

Per

In.

PSI

And

Inches

Lbs.

Sec.)

Amps

Inches

Approx.

Above

Inches

0.010

3/8

200

4000

3/8

1/4

0.10

130

180

0.010

0.021

3/8

300

6500

7/16

3/8

0.13

320

440

0.021

0.031

3/8

400

6600

7/16

1/2

0.16

570

800

0.031

0.040

1/2

500

9500

1/2

3/4

0.19

920

1200

0.040

0.050

1/2

650

10500

9/16

7/8

0.22

1350

–

0.050

0.062

1/2

800

12000

5/8

0.25

1850

–

0.062

0,078

5/8

1100

14000

11/16

1-1/4

0.29

2700

–

0.078

0.094

5/8

1300

15500

3/4

1-1/2

0.31

3450

–

0.094

0.109

5/8

1600

17500

15/16

1-5/8

0.32

4150

–

0.109

0.125

7/8

1800

18000

7/8

1-3/4

0.33

5000

–

0.125

Thickness

Electrode

Net

WeId

Welding

Minimum

(of thinnest

Diameter

Electrode

Time

Current

Overlap

piece)

Force

(Approx.)

Inches

Pounds

Cycles

Amps.

Inches

0.030

1/2

475

10,500

1/2

0.035

1/2

550

11,000

9/6

0.040

5/8

625

12,500

5/8

0.050

5/8

840

14,000

11/16

0.060

5/8

1050

15,500

3/4

0.075

3/4

1400

19,500

7/8

0.093

3/4

1800

24,000

0.109

3/4

2200

28,500

1-1/4

Thickness “T”

Diameter

Height of

Minimum Shear Strength

Diameter

Minimum

of Thinnest

Projection

(Single Projecting Only)

of Fused

Contacting

Outside Piece

Projection

“H”

Zone

Overlap

(Nominal)

“D”

Pounds

Minimum

“L”

(At Weld

Tensile

Interface

Strength

Below

70000

150000

70000

Up To

PSI

150000

And

Inches

PSI

Above

Inches

0.010

0.055

0.015

130

180

250

0.112

1/8

0.012

0.055

0.015

170

220

330

0.112

1/8

0.014

0.055

0.015

200

280

380

0.11 2

1/8

0.016

0.067

0,017

240

330

450

0.112

5/32

0.021

0.067

0.017

320

440

600

0.140

5/32

0.025

0.081

0.020

450

600

820

0.140

3/16

0.031

0.094

0.022

635

850

1100

0.169

7/32

0.034

0.094

0.022

790

1000

1300

0.169

7/32

0.044

0.119

0.028

920

1300

2000

0.169

9/32

0.050

0.119

0.028

1350

1700

2400

0.225

9/32

0.062

0.156

0.035

1950

2250

3400

0.225

3/8

0.070

0.156

0.035

2300

2800

4200

0.281

3/8

0.078

0.187

0.041

2700

3200

4800

0.281

7/16

0.094

0.218

0.048

3450

4000

6100

0.281

1/2

0.109

0.250

0,054

4150

5000

7000

0.338

5/8

0.125

0.281

0.060

4800

5700

8000

0.338

11/16

0.140

0.312

0.066

6000

–

7/16

3/4

0.156

0.343

0.072

7500

–

1/2

13/16

0.171

0.375

0,078

8500

–

9/16

7/8

0,187

0.406

0.085

10000

–

9/16

15/16

0.203

0.437

0,091

12000

–

5/8

0.250

0.531

0.110

15000

–

11/16

1-1/4

PROJECTION WELDING SCHEDULE GUIDE

FOR ONE PROJECTION:

FOR MORE THAN ONE PROJECTION:

CURRENT = 1T + .045 x 100,000 AMPS

CURRENT = 1T + .045 x 100,000 + 30% FOR EACH ADDITIONAL PROJECTION

TIME

= 2T x 100 HERTZ (CYCLES)

TIME

= 2T x 100 HERTZ (CYCLES)

= 2T x 6,000 LBS.

PRESSURE = 2T x 6,000 + 50% FOR EACH ADDITIONAL PROJECTION

SPOT WELDING LOW CARBON STEEL

1. Type of steel: SAE 1010

2. Material should be free from scale, oxides, paint, grease and oil.

3. Welding conditions determined by Thickness “T” of thinnest

outside piece.

4. Data for total thickness of pile-up not exceeding 4 “T”.

Recommended maximum ratio between two thicknesses: 3 to 1.

5. Electrode Material: Class 2 (Tuffaloy 77)

6. Minimum weld spacing is that spacing for two pieces for which

no special precautions need be taken to compensate for shunted

current effect of adjacent welds. For three pieces, increase

spacing 30 per cent.

SPOT WELDING GALVANIZED STEEL

1. Type of galvanized: 1.25 oz/ft2 nominal.

2. Material should be free from dirt, paint, grease and oil.

3. Welding conditions determined by thinnest of two pieces only.

Schedule is good for thickness ratios up to 2:1.

4. Electrode material: Class 1 or 2 (Tuffaloy 88 or 77).

5. Electrode nose design: Dome or truncated cone.

(from International Lead, Zinc Research Organization, Inc.)

PROJECTION WELDING DATA FOR LOW

CARBON AND STAINLESS STEEL

1. TYPES OF STEEL:

Low-Carbon-SAE 1010

Stainless-Types 309, 310, 316, 317, 321, 347 and 349.

(Non-Hardenable: Max. Carbon content 0.15%)

2. Material should be free from scale, oxides, paint, grease and oil.

3. Size of projection normally determined by thickness of thinner

piece, and projection should be on thicker piece where possible.

4. Data based on thickness of thinner sheet, and for two

thicknesses only.

5. Contacting overlap does not include any radii from forming, etc.

6. Weld should be located in center of overlap.

7. Projection should be made on piece of higher conductivity when

dissimilar metals are welded.

8. For diameter of projection “D” a tolerance of 0.003 in. in

material up to and including 0.050 in. in thickness and 0.007 in.

in material over 0.050 in. in thickness may be allowed.

9. For height of projection “H” a tolerance of 0.002 in. in material

up to and including 0.050 in. in thickness and 0.005 in. in

material over 0.050 in. in thickness may be allowed.

TUFFALOY

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