8/11/2017 Process of Percussion Welding (With Diagram)

Process of Percussion
Welding (With
Diagram)
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After reading this article you will learn about the

process of percussion welding with the help of suitable
diagrams.

In percussion welding two pieces are welded by a high

intensity short duration arc followed by very rapid or
percussive impacting of the workpieces. The molten
surfaces are then squeezed together by collision and
some of the metal is forced out to the side of the joint.

This process is quite similar to upset welding and flash

welding but is used for welding parts of the same
geometry and cross-section. In this process arc is
produced by very rapid discharge of stored electrical
energy across a rapidly decreasing air gap which is
immediately followed by application of pressure and the
parts are brought together in progressive percussive
manner.

There are three different methods of arc initiation in

percussion welding viz., low voltage with drawn arc,
high voltage breakdown, and ionising by a fusing tip.
With each method the energy source is a bank of
capacitors which is charged by a variable voltage
transformer cum rectifier unit and a simple diagram of
the setup is shown in Fig. 2.27(a).

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8/11/2017 Process of Percussion Welding (With Diagram)

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In low voltage drawn arc method a low voltage capacitor

is used and the workpieces are initially kept in contact
but are separated by an electromagnetic device at the
commencement of energy discharge. When the
workpieces are melted adequately they are brought
together under impact.

In high voltage breakdown of gap the pieces to be joined

are connected to the capacitor and are brought together
by spring or pneumatic pressure as shown in fig. 2.27
(b). As the gap reduces to the breakdown level the arc is
initiated and superficial melting takes place before the
pieces are brought together under impact. The voltages
required in this method are of the order of 103 volts
which being lethal the process is best handled in
automatic mode.

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8/11/2017 Process of Percussion Welding (With Diagram)

This process is widely used for connecting wires to

electrical equipment. The wire is usually in coil form
and is fed automatically and cut to size before feeding in
the next part. The process is very rapid, for example, 1
mm diameter wires with a charge voltage of 1000 volts
are brought together at a velocity of 1 m/sec within a
duration of less than 100 micro-second.

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In low voltage ionising tip method the arc is initiated by

fusing initial point of contact between the two pieces to
be welded. As the metal is melted it ionises the path
facilitating the initiation of the arc.

For joining wires to thicker metal parts a capacitor bank

charged to 100 volts is used. When wire touches the
workpiece under a momentary pressure a short length
at the tip is vaporised or splashed initiating the arc
which forms a molten metal droplet at the end of the
wire and a pool on the workpiece. As the wire keeps

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8/11/2017 Process of Percussion Welding (With Diagram)

advancing it plunges into the weld pool forming a

welded joint.

Percussion welding has been very successfully used for

welding of dissimilar metal combinations like copper to
Nichrome (80% Ni + 20% Cr), copper wire to 304
stainless steel (austenitic) plate, thorium to thorium or
thorium to zircaloy.

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Percussion welding is particularly good for joining small

diameter wires, even with widely different properties, of
0 050 to 0-400 mm diameter, in electronic industry. Also,
this process can be used for welding parts with pin-point
type projections formed or coined into the parts. This
localises the heat at the small areas so that the parts are
welded instantly due to melting and vaporisation at the
projecting areas.

, Metallurgy, Percussion Welding, Resistance

Welding Process, Welding Processes

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8/11/2017 Process of Percussion Welding (With Diagram)

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