175-4591 datasheet(52/54 Pages) ETC2

52 / 54 page

TUFFALOY

helpful suggestions

EXPULSION AT WELD INTERFACE

• Short Squeeze Time

• Low Weld Force

• Dirty – Scaly Material

• Poor Fit Up

• Insufficient Edge Distance

SURFACE EXPULSION/

ELECTRODE STICKING

• Short Squeeze Time

• Long Weld Time

• Short Hold Time

• Low Weld Force

• High Weld Current

• Dirty – Scaly Material

ELECTRODE MUSHROOMING

• Insufficient Cooling

• Low weld Force

• High Weld Current

• Small Electrode Face Area

• Long Weld Time

• Welder Head Impacts Work

LOW WELD STRENGTH

• Short Weld Time

• Low Weld Force

• Low Weld Current

• Small Electrode Face Area

• Poor Heat Balance

• Welds Too Close Together

EXCESSIVE WELD INDENTATION

• Long Weld Time

• High Weld Force

• High Weld Current

• Poor Fit Up

• Welder Head Impacts Work

INTERNAL CRACKS IN WELD NUGGET

• Short Hold Time

• Low Weld Force

• Dirty – Scaly Material

• Metallurgy of Material Welded

• Poor Head Follow Up

DISPLACED WELD NUGGET

• Electrode Misalignment

• Poor Heat Balance

• Poor Fit Up

CRACKS IN PARENT MATERIAL

• High Weld Force

• Insufficient Cooling

• Metallurgy of Material Welded

PROBLEM SOLVING

• Use standard RWMA design electrodes whenever

possible. Use the RWMA recommended electrode material

for the part being welded. Keep the electrodes aligned

normal to the working face. Only use offset electrodes

or weld at an angel when nothing else will work.

• Check the water deflector tubes each time you install

electrodes. They should be within one quarter inch of

the bottom of the water hole of the electrode.

• Confirm there is water flow from the electrodes,

transformer, control and other cooled components

before welding.

• Always use the proper size water hose, if removed check

for obstructions that might impede flow.

• When a set up will not be used for a period of time remove

the electrodes from the holders to avoid freezing into the

holder due to corrosion.

• Use fine emery cloth to dress electrode faces. If wear is

excessive remove from the machine and dress in lathe or

other controlled machine. Dressing electrodes with files

is not recommended because alignment and consistency

are not possible with this manual method.

• If the use of a hammer is necessary on resistance

welding machine or its components, use rubber,

plastic, brass, raw-hide or other soft material. Never

use a steel hammer.

• If a water leak is found repair as soon as possible, or

report it to the appropriate maintenance personnel.

• Check all mechanical connections in the secondary

connections. Check all shunts and cables for damage,

replace as needed.

• Perform maintenance to Resistance Welding equipment

as outlined in RWMA Bulletin 14.

• Keep in mind that sparks/expulsion are an indication

that something is not right at the weld. It could be

current, force, time, alignment and many other factors.

Take time, check your set up for variance from the

desired settings. Expulsion can be dangerous and

could also result in questionable product.

RESISTANCE WELDING

HELPFUL HINTS

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