The document discusses resistance spot welding of aluminum and aluminum alloys. It describes the resistance welding process, types of resistance welding including spot welding, and how spot welding is widely used in the automotive industry. It also outlines important considerations for spot welding aluminum, such as using higher current and ensuring good electrode and machine design to handle the different properties of aluminum compared to steel.
Technical Presentation on External Gear PPT
Introduction
A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which mesh with another toothed part to transmit torque.
Geared devices can change the speed, torque, and direction of a power source.
Gears almost always produce a change in torque, creating a mechanical advantage, through their gear ratio, and thus may be considered a simple machine.
The teeth on the two meshing gears all have the same shape. Two or more meshing gears, working in a sequence, are called a gear train or a transmission.
A gear can mesh with a linear toothed part, called a rack, thereby producing translation instead of rotation.
The gears in a transmission are analogous to the wheels in a crossed belt pulley system. An advantage of gears is that the teeth of a gear prevent slippage.
Frame is a ladder shaped structure with two longitudinal rails/beams (Frame side members) and properly located many integrating and reinforcing cross members, which form the ladder structure that is used as the interface/platform between the power package and the body package in Automobiles.
Technical Presentation on External Gear PPT
Introduction
A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which mesh with another toothed part to transmit torque.
Geared devices can change the speed, torque, and direction of a power source.
Gears almost always produce a change in torque, creating a mechanical advantage, through their gear ratio, and thus may be considered a simple machine.
The teeth on the two meshing gears all have the same shape. Two or more meshing gears, working in a sequence, are called a gear train or a transmission.
A gear can mesh with a linear toothed part, called a rack, thereby producing translation instead of rotation.
The gears in a transmission are analogous to the wheels in a crossed belt pulley system. An advantage of gears is that the teeth of a gear prevent slippage.
Frame is a ladder shaped structure with two longitudinal rails/beams (Frame side members) and properly located many integrating and reinforcing cross members, which form the ladder structure that is used as the interface/platform between the power package and the body package in Automobiles.
The chassis frame supports the various components and the body, and keeps them in correct positions.
The frame must be light, but sufficiently strong to withstand the weight and rated load of the vehicle without having appreciable distortion.
It must also be rigid enough to safeguard the components against the action of different forces.
The chassis design includes the selection of suitable shapes and cross-section of chassis-members.
Titanium is named after the Titans, the
powerful sons of the earth in Greek mythology.
• Titanium is the forth abundant metal on
earth crust (~ 0.86%) after aluminium, iron and
magnesium.
Titans
homepage.mac.com
Rutile (TiO2)
mineral.galleries.com
Ilmenite (FeTiO3)
• Not found in its free, pure metal form in
nature but as oxides, i.e., ilmenite (FeTiO3)
and rutile (TiO2).
• Found only in small amount in Thailand...
An EV is a shortened acronym for an electric vehicle. EVs are vehicles that are either partially or fully powered on electric power. Electric vehicles have low running costs as they have fewer moving parts for maintenance and also very environmentally friendly as they use little or no fossil fuels (petrol or diesel).
Design of Switched Reluctance Motor for Three Wheeler Electric Vehicleidescitation
Switched Reluctance M achines (SRM ) offer
attractive attributes for automotive applications. Low cost, high
reliability, and competitive weight and efficiency combine to
make the switched reluctance (SR) motor drive a strong
candidate for application in future electric vehicle (EV)
propulsion systems. This paper proposes a methodology to
determine separately the peak and continuous power ratings
of a switched reluctance motor (SRM) for electric propulsion
of an electric vehicle (EV).same machine have to deliver peak
and continuous power for different road load condition of
vehicle. Then gives switched reluctance design guidelines for
battery operated electric vehicles. Finally, it presents the
design and simulation of a switched reluctance motor power
train.
Artech Welders Private Limited took roots in 1994 with the dream of manufacturing Capacitor Discharge (CD) projection welding machines. Powered by a vision to blend power saving with aesthetics, Artech has today germinated into a force to reckon with in the field of resistance welding. A wide range of end users embrace the quality welding that Artech offers. They include manufacturers of automobile sheet metal components, stainless steel impellers, sheet metal products, diamond tools like cup wheels and core drills, hollow metal doors, auto electricals, control panels, stainless steel cookware and kitchenware to name a few.
The chassis frame supports the various components and the body, and keeps them in correct positions.
The frame must be light, but sufficiently strong to withstand the weight and rated load of the vehicle without having appreciable distortion.
It must also be rigid enough to safeguard the components against the action of different forces.
The chassis design includes the selection of suitable shapes and cross-section of chassis-members.
Titanium is named after the Titans, the
powerful sons of the earth in Greek mythology.
• Titanium is the forth abundant metal on
earth crust (~ 0.86%) after aluminium, iron and
magnesium.
Titans
homepage.mac.com
Rutile (TiO2)
mineral.galleries.com
Ilmenite (FeTiO3)
• Not found in its free, pure metal form in
nature but as oxides, i.e., ilmenite (FeTiO3)
and rutile (TiO2).
• Found only in small amount in Thailand...
An EV is a shortened acronym for an electric vehicle. EVs are vehicles that are either partially or fully powered on electric power. Electric vehicles have low running costs as they have fewer moving parts for maintenance and also very environmentally friendly as they use little or no fossil fuels (petrol or diesel).
Design of Switched Reluctance Motor for Three Wheeler Electric Vehicleidescitation
Switched Reluctance M achines (SRM ) offer
attractive attributes for automotive applications. Low cost, high
reliability, and competitive weight and efficiency combine to
make the switched reluctance (SR) motor drive a strong
candidate for application in future electric vehicle (EV)
propulsion systems. This paper proposes a methodology to
determine separately the peak and continuous power ratings
of a switched reluctance motor (SRM) for electric propulsion
of an electric vehicle (EV).same machine have to deliver peak
and continuous power for different road load condition of
vehicle. Then gives switched reluctance design guidelines for
battery operated electric vehicles. Finally, it presents the
design and simulation of a switched reluctance motor power
train.
Artech Welders Private Limited took roots in 1994 with the dream of manufacturing Capacitor Discharge (CD) projection welding machines. Powered by a vision to blend power saving with aesthetics, Artech has today germinated into a force to reckon with in the field of resistance welding. A wide range of end users embrace the quality welding that Artech offers. They include manufacturers of automobile sheet metal components, stainless steel impellers, sheet metal products, diamond tools like cup wheels and core drills, hollow metal doors, auto electricals, control panels, stainless steel cookware and kitchenware to name a few.
Fundamentals of Laser Welding. Learn what laser welding is and how it can help you. For more information on Miyachi Unitek laser welders please visit our site at http://www.miyachiunitek.com/Products_LaserWelding
Mountain Electric Bicycle have as of late been presented, permitting one to effortlessly cross slopes and dispensing with the requirement for a different vehicle to ship them to the top. Though battery fueled bikes are a late marvel, control helped bicycles have been with us for over a hundred years. http://www.citecycles.com/e-bikes-haibike.php
What to consider when welding dissimilar materials - WeldPulseWeldPulse
This is a guideline written to highlight the major considerations when welding dissimilar materials. The purpose of this guide is to identify the factors affecting the dissimilar weld and their significance.
After going through this, you will be carrying in mind a list of factors to be considered while making any decision on welding two dissimilar materials.
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Manufacturing technology I ME 8351 joining process DrPETERPRAKASH
This is very much useful for engineering students, Teachers and industrialist. Adequate knowledge of the concept and principles of welding and welding process used in various industries.
Autogenous laser welding of the AA6082-T651 aluminium alloy was investigated with 3 lasers, namely a pulsed laser of 300W, a disk laser of 4kW and a laser marker of 70W. First, the hot cracking susceptibility was studied with two conventional laser welding equipment, without using filler material or heat treatment. Additionally, an attempt was made to weld with a laser marking equipment. Most of the welds made were laser seam welds but, some continuous and laser spot welds were also tested. As each laser was operated with different parameters, more than 400 welds were obtained with a wide range of parameters. Selected welds were studied with visual inspection, dye penetrant inspection (DPI), optical microscopy and scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDS). Results indicated that welds with pulse laser beam tend to develop hot cracking, due to the segregation of silicon-rich low melting point eutectics to the grain boundaries and the development of contraction stresses during solidification. On the other hand, positive results were found with continuous welding since this process results in much longer solidification times and lower stresses. Finally, promising results were obtained with the laser marking machine, which produced high aspect ratio laser seam welds without hot cracking and a penetration of 1 mm using 99.9% of overlap factor. These welds were crack free due to their small weld pool, avoiding segregation effects, and to the heat build-up of successive spots, what had similar effect to solidification in continuous welding.
Demand of welding increase of new materials.
-- ceramics and metal matrix composites.
-- High strength low-alloy (HSLA) steels
Lack of skilled labours
Traditional welding techniques are costly
Safety concerns.
Need to improve the total cost effectiveness of the welding
Lalit Yadav
An electric vehicle, also called an EV, uses one or more electric motors or traction motors
for propulsion instead of the traditional fossil fuel.
• First electric carriage was built in 1830s and the first electric automobile was built in 1891
in the United States.
• Types : Battery electric Vehicle
Hybrid Electric Vehicle
Plug-in Hybrid Electric Vehicle
Fuel Cell Electric Vehicle
• Electric vehicles will play a pivot role in changing the environment and economy around
the globe in the next two decades.
One of the welding processes that used in Engineering field is the flux cored arc welding. There are several types of welding processes similar to this, but flux cored arc welding has its unique features.
Thanks for the colleagues who give this slides to publish.
Welding is a fabrication process used to join materials, typically metals or thermoplastics, by causing fusion, leading to the creation of a strong, permanent bond. Various welding processes exist, each with its own techniques, applications, and suitability for different materials and conditions. Some of the common welding processes include:
Shielded Metal Arc Welding (SMAW):
Commonly known as "stick welding," it uses a consumable electrode coated with flux to create the weld.
It's versatile and widely used in construction, maintenance, and repair work.
Gas Metal Arc Welding (GMAW/MIG - Metal Inert Gas):
Uses a continuous solid wire electrode and a shielding gas (typically argon or a mix of gases) to protect the weld area from atmospheric contamination.
Generally used in manufacturing, automotive, and construction industries.
Gas Tungsten Arc Welding (GTAW/TIG - Tungsten Inert Gas):
Uses a non-consumable tungsten electrode and a separate filler material if needed.
Often used for thin materials, critical welds, or where precise control is necessary.
Flux-Cored Arc Welding (FCAW):
Similar to MIG welding but uses a tubular wire filled with flux instead of a solid wire and external shielding gas.
Commonly used in heavy equipment manufacturing and construction.
Submerged Arc Welding (SAW):
Involves feeding a continuous, solid filler wire electrode and granular flux over the weld zone.
Ideal for heavy industrial applications due to its high deposition rates.
Resistance Spot Welding (RSW):
Joins metals by applying pressure and passing current through the metals using copper alloy electrodes.
Widely used in automotive manufacturing and sheet metal applications.
Oxy-Fuel Welding (OFW):
Uses fuel gases and oxygen to weld and cut metals.
Still used for maintenance and repair work, though its use has declined in favor of other processes.
Electron Beam Welding (EBW) and Laser Beam Welding (LBW):
Utilize highly focused beams of electrons or lasers to create high-quality welds in precise and delicate applications, often in aerospace or electronics industries.
Each welding method has its advantages and limitations, making certain techniques better suited for specific applications based on factors like material type, thickness, required strength, and the environment in which the welding will be performed.
Welding processes continue to evolve, with advancements in technology improving efficiency, precision, and safety, and newer techniques being developed to cater to specific industrial needs and challenges.
2. Contents:
• Aluminum in industry
• Resistance welding (Definition ,Principle ,Types)
• Spot (RSW) in automotive industry
• Conditions and rules must be applied in Spot welding of AL
• Contact-Resistance Measurement
• Equipment for RSW of aluminum
• Electrodes for (RSW) aluminum
• Problems connected with electrodes by Spot (RSW)
• Arc-Cleaning Method of Spot Welding Aluminum
• Defects in spot welds
• Conclusion
• References
3. Aluminum In Industry
• According to the newest studies, automotive industry
tends to use light alloys like aluminum and magnesium
alloys. Companies more often use aluminum as an
alternative material for vehicle body.
• The most popular method of joining body sheets is
resistance spot welding. Aluminum and its alloys series
5xxx and 6xxx can be connected by this technique.
6. (RSW) Principle cont.
• The general heat generation formula in
(RSW) is
Heat=(I^2)*R*t*K
Where: I = Electrical current (Ampair)
R= Electrical resistance (Ohm)
t = Weld time (HZ)
K= thermal expansion coefficient
7. Resistance welding
• Advantages:
(1) Very little warpage of the metal (Sheet metal).
(2) The process can accurately controlled and the
weld constantly uniform.
(3) Suitable for all automatic production.
(4) Clean and environmentally friend.
(5) Operator safety because of law voltage.
8.
9. Resistance Welding
• Types (all types based on the same principle )
(1) Spot welding (Most common in industry)
13. Spot (RSW) in automotive industry
• Resistance Spot Welding (RSW) is widely used
in the high-volume manufacture of sheet metal
products. The automotive industry has relied on
RSW as a principal joining method for many
decades. A typical car contains between 2000
and 3000 spot welds.
• General Motors Yukon (SUV), with lightweight
spot welded all-aluminum rear door (tailgate).
Manufactured at 500,000 units per year.
14. Spot (RSW) in automotive industry
Cont.
• Advantages of RSW in high-volume automotive
manufacturing
(1) Inexpensive (per-weld cost ~€ 0.05)
(2) Rapid process (< 1 second per weld)
(3) Ease of automation (flexible process)
(4) No per-weld consumables (i.e. no
issues of piece-cost, inventory, additional
weight or recycling difficulties)
(5) Low training costs (in manual
operations).
15. Conditions and rules must be applied in
Spot welding of AL
• Resistance Spot Welding of aluminum and its
alloys involves applying high power welding
guns because welding current must be 2–3
times higher than in case of steel but the welding
time is 1/3 weld time of steel.
• The main of that is 3 times higher than in case of
steel its thermal and electrical conductivity. It
means the electric parameters (current and
voltage) must be controlled more precisely in
narrower window of time.
16. Contact-Resistance Measurement
• Because of the resistance of the oxide layers and its effect
on resistance welding, it is quite important to know the contact
and total resistance of the sheet samples to be welded. This
device uses low currents through the weld while measuring
the voltage drop and thus calculating the weldment initial
resistance
17. Equipment for RSW of aluminum
• AL Can be spot welded by all conventional RSW
systems and power supplies, if they meet the following :
(1) High electrode force (4-8 KN)
(2) High welding current (20-45 KA)
(3) Minimal deflection in gun arms (<1 mm)
(4) Efficient water cooling of electrodes ,gun arms ,& all
current-carrying components
(5) Low-friction force actuator, to maintain weld force as
electrodes move during weld formation (i.e. good follow-
up).
18. Electrodes for (RSW) aluminum
• (Because of Lower Resistance of Aluminum
Than Steel, More Current is Needed to Make the
Weld)
• The Main properties of ideal electrodes:
(1) Max electrical and thermal conductivity
(2) Max hardness or resistance to deformation
(3) Tip design which reduce wear
(4) Minimum tendency to alloy with the
material being welded
19. Alloys used as a material in AL spot
welding electrodes
• The copper alloy RWMA Class I (a copper-
cadmium alloy) has found wide acceptance as
electrode material for aluminum spot, roll-spot and
seam welding.
• The RWMA Class II copper alloy, which is heat-
treatable and available in cast form, has also been
used by many fabricators for spot, roll-spot and
seam welding. Because of superior hardness, this
is especially true for the latter two welding
processes which results in greater electrode life.
21. Arc-Cleaning Method of Spot Welding Al
• High frequency arc:
Arc cleaning is a relatively new approach to the resistance welding
aluminum alloys. This approach is the result of the sputtering action
of positively charged argon ions which displaces the oxide from the
negatively charged sheet surface, as shown in figure ,Although this
technique has shown considerable success, additional equipment
and power sources are required
22. Defects in spot welds
• Unconformities which can appear in spot welds
cause the spot welds can have less strength and
can lead into total destruction of manufacturing parts
of cars bodies.
• The typical unconformities of spot welds are :
(1) Cold weld
(2) Small-diameter nugget
(3) bad shape of welding nugget
(4) cracks inside/around welding nugget
(5) deep indentation of welding electrodes in
sheets.
25. Conclusion
• the RSW process of AL and its alloys is
finding a wide range of applications in
joining technology. Its offered new
perspectives for innovative working and
opportunities for cost saving and high
productivity particularly in vehicle
manufacturing.