Welding parameters are typically chosen from experience, records, or performing a parametric study. If this information is unavailable, the following graph can provide a starting point for weld schedule development.
To use this graph:
Print the graph.
Find the desired penetration level.
Draw a vertical line from this point until it intersects with the power curve of the desired material.
Draw a horizontal line from this point until it intersects with the heat input axis.
Use 50kV accelerating voltage and welding speed and current to achieve the required heat input.
Resistance Welding
Suggested Settings for Welding Low Carbon Steel (Based on 1010)
Material In. Thick
E Tip In. Dia.
Class
Electrode Weld Force, lbs.
Amps
Cycles of CO
HT
Impulses
Min. Avg. Tensile lbs. Shear
Min. Avg. Spot Dia.
0.010
0.12
2
100
3,200
1
2
1
140
0.060
0.021
0.19
2
200
5,600
1
3
1
345
0.100
0.031
0.19
2
300
7,500
1
4
1
695
0.140
0.040
0.25
2
450
9,000
1
5
1
1,000
0.160
0.050
0.25
2
600
11,000
2
5
2
1,475
0.180
0.062
0.25
2
800
12,200
2
5
3
2,170
0.200
0.078
0.31
2
1,100
13,700
2
5
3
2,920
0.220
0.094
0.31
2
1,450
17,000
2
5
4
3,710
0.245
0.109
0.38
2
1,800
19,000
2
5
5
4,532
0.260
0.125
0.38
2
2,200
21,000
2
5
6
5,310
0.280
0.156
0.44
2
3,000
24,200
2
5
9
7,300
0.320
0.187
0.50
2
4,000
28,300
2
5
12
11,500
0.350
0.250
0.62
2
6,700
35,300
2
5
19
18,600
0.385
Suggested Settings for Spot Welding Stainless Steel (Based on Aisi-304)
Material In. Thick
E Tip In. Dia.
Class
Electrode Force, lbs.
Amps
Cycles of CO
Cycles of HT
Impulses
Min. Avg. Tensile lbs. Shear
Min. Avg. Spot Dia.
0.016
0.12
2
300
3,900
1
*1
2
260
0.085
0.020
0.16
2
450
4,300
1
1
2
345
0.100
0.025
0.16
2
520
4,950
1
2
2
495
0.120
0.032
0.19
2
750
5,750
1
3
2
695
0.140
0.040
0.19
2
900
6,600
1
4
2
1,000
0.160
0.051
0.25
2
1,200
8,150
2
5
2
1,475
0.180
0.062
0.25
2
1,500
9,500
2
5
2
2,170
0.200
0.078
0.25
2
1,700
10,200
2
5
3
2,920
0.220
0.081
0.31
2
1,900
11,400
2
5
3
3,025
0.225
0.091
0.31
2
2,500
13,000
2
5
4
3,560
0.240
0.109
0.38
2
3,300
14,700
2
5
5
4,532
0.260
0.125
0.38
2
4,000
16,200
2
5
6
5,310
0.280
* 1 Cycle, 1 Phase
Suggested Settings for Spot Welding Aluminum Alloys (Based on 2014-T6 & 2024-T3)
