Capacitor Discharge Welding

Percussion Welding
Magnetic Force (AC)
Stud Welding

Capacitive Discharge Welding

Lesson Objectives
When you finish this lesson you will
understand:
The mechanism of percussion
welding and magnetic force welding
Applications of use of these methods

Learning Activities
1. View Slides;
2. Read Notes,
3. Listen to lecture
4. Do on-line
workbook

Keywords
Percussion Weld, Capacitor Discharge, Nib, Magnetic Force Weld

Percussion Welding
(PEW): A resistance
welding process which
produces coalescence of the
abutting members using heat
from an arc produced by a
rapid discharge of electrical
energy. Pressure is applied
percussively during or
immediately following the
electrical discharge.

Applications:

Cueman, Process Model for

Percussion Welding,
Welding Journal, Sept, 1989

can be used to join like and unlike

metals that cannot usually be flash or stud welded. It is
used for fine wire leads to filaments such as in lamps and
electrical components.

AWS Welding Handbook

Variations of Percussion Welding

Capacitor Discharge, Low V, Nib Start

Capacitor Discharge, Low V, High Frequency Start
Capacitor Discharge, High V
Magnetic Force Method (AC)

Metals Handbook, ASM, 1983

Low Voltage: Hand held & bench type welders

High Voltage: More uniform arc, No Nib start , More control
Transformer: for Magnetic-force, weld made during first 1/2 cycle
Metals Handbook, ASM, 1983

Low Voltage
Hand Held
Unit

AWS Welding Handbook

Metals Joined
Like Metals
Tantalum Alloys
Copper Alloys
Aluminum Alloys
Nickel Alloys
Low-carbon steel
Medium-carbon steel
Stainless Steels

Other Dissimilar Wires

Thermocouple Wires
Molybdenum Wires
Nb-1Zr
85Zr-15Nb
Tantalum

Welded to Copper
Gold
Silver
Copper-tungsten
Silver-tungsten
Silver-cadmium oxide
Molybdenum
Diffusion during prolonged
high temperature exposure
may produce weak or
embrittled
structures.Transition joints
of a compatible third
material may help.

Metals Handbook, ASM, 1983

Welding Energy
1
2
E CV
2
E = energy in watt-seconds (joules)
C = capacitance in farads
V = voltage
Amount of Energy Needed to Make Joint Depends on:
Cross-sectional area of joint
Properties of work metal or metals
Depth to which metal is melted on workpieces

Metals Handbook, ASM, 1983

Arc Time (Arc Duration)

Interval that begins when arc is initiated and ends when workpieces touch

Factors Affecting Arc Time

Work Metal or Combination
Mass of Moving Workpiece
Nib Dimensions
Welding Voltage
Welding Current
Welding Force
Synchronization of Machine Functions

Generally, the
shortest weld time
allowing some
penetration
into each part
while minimizing
heating is
recommended

Mechanical Properties vs Weld Time

Weld Time
Bakshas, The quality of capacitor deischarge< Automatic Welding, Mar., 1981

Heat Affected Zone

(Very Narrow)

Lower Melting Temp

Only a few
Millionths
Inch to 0.025

Higher Melting Temp

Because HAZ is so small

Heat treated metals can be welded without softening
Heat sensitive components near weld unaffected

Welding Current

Peak Current Density

=300,000 A/in2

Polarity:
No Effect for Like materials
Positive polarity for:
Large Cross Section
Higher Melting Point
Higher Thermal Conductivity

Welding Force
Force Supplied By:
Electromagnet
Gravity
Cam-activated Direct Drive
Spring
Pneumatic

Force must be strong enough

to accelerate moving part
over short gap.
Peak loads = 15 - 30 ksi
Wire Size
5 mils
0.01

Impact Velocity
10-60 in/s
80-150 in/s

Because the force applying unit may rebound and put a

tensile loading on welded part, a means of damping must be
provided.

Gravity Unit
Thompson, Attachment of Thermocouple Instrumetation,
Welding Journal, June 1982

Spring Loaded Unit

Thompson, Attachment of Thermocouple Instrumetation,
Welding Journal, June 1982

Advantages of Percussion Welding

Brevity of arc limits melting and heating. Heat-treated and cold
worked materials can be welded without annealing.
No Filler Metal required, No cast structure at interface.
Charging rate is low and controlled, Line power line demand
Can tolerate some contamination on faying surface.

Limitations of Percussion Welding

Limited to butt joints
Total area limited
Similar metals can usually be joined more
economically by other processes.
Usually confined to joining of dissimilar metals not
normally considered weldable

Variations of Percussion Welding

Capacitor Discharge, Low V, Nib Start

Capacitor Discharge, Low V, High Frequency Start
Capacitor Discharge, High V
Magnetic Force Method (AC)

Air Cylinder applies

initial force to bring
contact to nib

Electromagnetic
Force applied during
Welding

Metals Handbook, ASM, 1983

Schlegel, All About Percussion Welds,

Welding Design & Fabrication, Oct. 1990

AWS Welding Handbook

AWS Welding Handbook

AWS Welding Handbook

Arc Time is a Function of:

Magnitude of magnetic force
Timing of the magnetic force with relation to welding
current
Inertia or mass of the moving parts in the force system
Magnitude of the welding current and the diameter of the
projection

Acceleration of the moveable head:

Directly proportional to the magnetic force applied
Inversely proportional to the mass

Section through a Silver Contact (Top) to a Brass Terminal

AWS Welding Handbook