Advantages And Disadvantages Of Upset Welding

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Kerstens (2009, p. 11), describes the upset welding process as: The two ends of a work-piece are brought together under a high welding or upsetting force before the application of the welding current. Due to the contact resistance of the two workpieces the interface becomes warmer and when the material is warm enough, an extra upsetting pressure is applied, material extrudes out-wards forming an upset, and the two workpieces join. The literature related to this process to date has been limited (KERSTENS, 2009). Resistance upset welding, unusually of other resistance welding processes, is a solid-state welding process. It involves the interaction of electrical, thermal, mechanical and metallurgical phenomena (KERSTENS, 2009). In comparison with fusion welding processes, the metallurgical properties and chemical composition are not significantly modified leading to better mechanical properties (KANNE, 1994). Simplicity, welding speed, capability of remote control and independence of welding quality from the operator skill are the other advantages of this process (KANNE, 1994). Temperatures are lower than for fusion welding, and there are no transformations or solidification stresses induced by melting. The fact that is a solid-state process enables to weld within the supercooled liquid temperature (ΔTx), and hence below the BMG crystallization temperature (Tx). This feature allied to short welding cycles and high cooling rates allows for the hypothesis that, with correct

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