A weld schedule controls your resistance welding process. It includes welding current, time, electrode force, and electrode size. You need a well-designed weld schedule to achieve high-quality, repeatable welds. Follow these steps to create an effective weld schedule.

Step 1: Determine the Material Properties

Know Your Materials

Start by identifying the properties of your materials. Document the metal type, thickness, and electrical resistance. You need this information to select the right welding parameters. Reference the RWMA welding manual for baseline specifications.

Step 2: Select the Welding Current

Calculate the Right Amperage

Welding current is the electrical power that flows through the metal during welding. Base your current selection on material thickness and electrical resistance. Thicker materials require higher welding current. The metal type also affects your current requirements.

Step 3: Determine the Welding Time

Set Your Weld Duration

Welding time determines how long current flows through the metal. Consider material thickness, welding current, and desired weld strength. Thicker materials need longer welding times. Stronger welds also require extended duration.

Step 4: Select the Electrode Force

Apply the Correct Pressure

Electrode force is the pressure you apply to the metal during welding. Choose your force based on material thickness and hardness. Harder materials require higher electrode force to achieve proper penetration.

Step 5: Determine the Electrode Size

Choose the Right Electrode Dimensions

Electrode size determines how you apply force to the metal. Select your electrode based on weld surface area and desired penetration depth. Larger electrodes work better for bigger surface areas. They also provide deeper penetration when needed.

Step 6: Test the Weld Schedule

Verify Your Weld Quality

Test your welds after creating the schedule. Visual inspection alone won’t determine weld quality. Use destructive testing methods like a pushout tester. You can also employ non-destructive methods such as force sensors or weld current monitors.

Create Consistent, Quality Welds

Creating a weld schedule requires thorough understanding of your materials and processes. Follow these steps to design an effective schedule. Your schedule will produce high-quality, repeatable welds. Always test your welds to verify they meet strength and quality requirements.

Get Expert Help

Have more questions? Consult with one of our resistance welding experts. We’ll help you determine the best solution for your specific application.