Resistance Welding with Homopolar Generators

摘要

This research evaluated the applicability of high power homopolar generator resistance welding to a variety of engineering alloys in frequently used shapes. Upset butt type welds were made in 19 different alloys and five dissimilar metal couples. To produce the welds, a welding fixture was designed and built. Generator variables studied were rotor speed and field excitation current. Fixture variables included upset force and the time of its application. Specimen variables included the material and joint design. Weld evaluations were based on metallography, microhardness traverses, and tensile tests. A finite-difference mathematical model of a homopolar pulse resistance weld was used to interpret results. Findings indicate that homopolar pulse resistance welding can become an important welding process. Process features include rapid welding, large cross section welding, and power lines working without drain. The process should reduce costs and construction time for welding-dependent industries.