How should the welding current and electrode pressure be coordinated in an energy storage spot welding machine to improve welding quality?

The welding current and electrode pressure are crucial factors affecting welding quality. How they are coordinated can greatly impact the welding process and improve the quality of the weld.

When the welding current is high, the electrode pressure should also be increased. The critical condition for coordinating these two parameters is to avoid splashing. This condition varies depending on the type of material being welded, whether soft or hard. The electrode applies pressure to the workpiece, typically ranging from several to thousands of newtons.

Electrode pressure is an important parameter during spot welding. Excessive or insufficient pressure can reduce the load-bearing capacity of the weld and increase its dispersion, especially affecting its resistance to tensile loads.

Excessive electrode pressure can lead to reduced plasticity and increased dispersion in the welding area, particularly affecting its resistance to tensile loads. Conversely, insufficient electrode pressure may result in inadequate plastic deformation of the metal in the welding area, causing rapid heating due to excessive current density and resulting in severe splashing. This not only alters the shape and size of the weld pool but also contaminates the environment and poses safety hazards, which is absolutely unacceptable.

High electrode pressure increases the contact area in the welding zone, reducing total resistance and current density, and increasing heat dissipation in the welding zone. As a result, the size of the weld pool decreases, and in severe cases, incomplete penetration defects may occur.

It is generally recommended to increase the welding current or welding time appropriately while increasing the electrode pressure to maintain the heating level of the welding zone. Additionally, increased pressure can eliminate adverse effects on weld strength caused by pressure fluctuations resulting from factors such as gaps in the workpieces or uneven steel stiffness. This not only maintains weld strength but also significantly improves stability.

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