About this Abstract |
| Meeting |
2025 AWS Professional Program
|
| Symposium
|
2025 AWS Professional Program
|
| Presentation Title |
Physics of High-Frequency Electric Resistance Welding (HF-ERW): The Relationship Between Weld Point Location, Upsetting, and Process Parameters |
| Author(s) |
Daniele D. G. Calista, Greg Lehnhoff, Patricio Mendez |
| On-Site Speaker (Planned) |
Daniele D. G. Calista |
| Abstract Scope |
This report presents a new understanding of the physics of HF-ERW, particularly how weld point location, or vee length, is a responsive process parameter that dictates the upsetting characteristics during welding. HF-ERW is a continuous process in which two weld interfaces are resistively heated by an induced current. As material approaches the weld point, a melt evolves on the interfaces and is expelled due to electromagnetic forces. The amount of expelled material directly affects weld point location and vee length. A new set of coupled mathematical expressions were developed for any alloy composition to capture the effects of input power, mill speed, skelp thickness, line frequency, and vee angle on vee length, all of which required understanding transient ablation. The model accurately explains the results in literature and from mill trials. The model predicts an increased vee length decreases the actual length of upsetting, resulting in decreased upset force. Current state-of-the-art considers mill geometry as the main driver of upsetting, which does not consider the weld point as a responsive parameter. The newfound ability to predict weld point location and upset force is expected to enable the development of HF-ERW process maps for a wide range of alloys and procedures. |
| Proceedings Inclusion? |
Undecided |