Homopolar Pulse Resistance Welding of Rails and Vehicle Components

摘要

Results of research carried out on three tasks is described. The primary task, the homopolar resistance butt welding of railroad rails, was performed to: (1) prove the technical feasibility of welding rails using the homopolar pulse resistance welding process (HPRW); (2) estimate the cost of producing in-track welds using the HPRW process; and (3) develop a design for a commercial in-track HPRW system. It was found that welds having 100 percent efficiency could be produced by the process. The second task was selected by the Ford Motor Company and the third by General Motors. The objectives of the Ford task included: (1) proving the technical feasibility of making mash-lap seam welds in typical drawn sheet metal industrial piece parts using the HPRW process; and (2) estimating the cost of producing HPRW seam welds. The objectives of the General Motors task were similar; its application was the attachment of the bolt flange to the steel pipe which constitutes a locomotive drive shaft.