Definition
The current passed during the weld time is too high for the welding
conditions.
Same as: over-current condition, hot weld.
Description
Current is too high for the combination of electrode caps in use, their
condition and contact area, the weld time, the weld force, and the materials
being welded.
Detection
Detectable evidence may include:
Significance
Quality, Workplace Issues, Cost, Downtime, Maintenance, Throughput (cycle
time; PPH), are all potentially affected by this condition. Special
considerations are noted below:
Quality: Excessive indentation and expulsion
may weaken the weld and be visually unacceptable. Expulsion can adhere
to customer visible surfaces.
Workplace Issues: Expulsion forms a steel grit that
contaminates weld shop equipment and paint shop processes.
Cost:
- Reduction in tip life may increase welding costs.
- Excess current use increases energy costs.
Downtime: Expulsion can accumulate (slag) and cause
arcing, short-circuiting, or equipment malfunctions resulting in downtime
if not resolved during preventive maintenance.
Subordinate Causes
- nominal current set too high
- incorrect stepper in use
- stepper not reset after cap change/redress
- tip contact area too small
- wrong cap type in use
WeldHelp: To Issue/Cause
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