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Aluminum Coated Steel

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Aluminum Coated Steel. Resistance Welding . Learning Activities View Slides; Read Notes, Listen to lecture Do on-line workbook. Lesson Objectives When you finish this lesson you will understand:. Keywords. Aluminized Coated Steel. Hot Dipped (continuous or batch) Electroplated

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Presentation Transcript
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Resistance Welding

  • Learning Activities
  • View Slides;
  • Read Notes,
  • Listen to lecture
  • Do on-line workbook
  • Lesson Objectives
  • When you finish this lesson you will understand:

Keywords

slide3

Aluminized Coated Steel

  • Hot Dipped (continuous or batch)
  • Electroplated
  • Thermal Spraying
  • Powder Coating with Fusion
  • Diffusion Coating

We will consider these

slide4

Hot Dipped Aluminum Coating

Type 1: Al - 8% Si (Oxidation Resistance Up to 1200F - 649C)-

Reduced Formability

T1-40 = 0.40 oz/ sq ft (0.001 inch thick)

T1-25 = 0.25 oz/ sq ft (0.0005 inch thick)

Type 2: Commercially Pure Al (Atmospheric Resistance at RT)

Lower Electrical Resistance

0.75 oz/ sq ft (0.002 inch thick)

slide5

Hot Dipped Aluminum Coating

Type 2

Al

Iron-Aluminide

Fe

ASM Handbook , Vol 1, 1990

slide7

Diffusion Aluminizing

Pure Aluminum Coating + Diffusion Heat Treatment

(Applied by Any of the previous processes) (Furnace Heat Treatment)

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Welding Aluminum Coated Steels

Spot Welding

  • Welding Current 20-50% higher than uncoated steel
  • Electrode Force 20-50% higher than uncoated Steel
  • Weld Time 40-60% longer than uncoated steel
  • Electrode Dressing somewhat more frequent than Galvanized Steel
  • Class II Truncated Cone Electrodes have been successful
  • More electrode indentation with type 2 Aluminized Sheet because it has lower resistance than type 1 Aluminized & generally Thicker Coating
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Welding Aluminum Coated Steels

Projection Welding

Benefit of Projection Welding:

Reduces need for frequent electrode dressing

  • Type 1 coating
  • Recommend slightly larger projects than for Uncoated steel
  • Normally flat class II Electrodes Recommended
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Welding Aluminum Coated Steels

Seam Welding

  • AWS Recommendations:
  • 20 - 50% greater welding current than bare steel
  • 20 - 50% greater pressure than bare steel
  • Class II wheels wit Type 1 Material
  • Pick up of Aluminum on Wheel must be countered
    • Knurled Drive Wheel
    • Power Brushes
  • Large amount of flood water
  • Mash seam welding is sometimes hampered by the refractory Oxide present

AWS Welding Handbook

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Welding Aluminum Coated Steels

ERW & High-Frequency Seam Welding

  • Both 60 Hz and High Frequency Welds can be made
  • Edges must be square & free of Aluminum to prevent Aluminum Oxide, thus Centerline defects
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Welding Diffusion Aluminized Metals

Close to the same as welding uncoated steel with one exception noted below

Aluminum Above 1% in the Weld Can Significantly Reduce Ductility and Cause Embrittlement

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