Resistance Welding Laboratory
Research, Testing and Development for Resistance Welding Applications
Weld Systems Integrators operates an advanced resistance welding laboratory for weld testing, process development, metallurgical evaluation, weld failure analysis, and production validation. Our welding lab helps manufacturers develop and optimize resistance welding processes, evaluate weld quality, determine material weldability, establish production weld schedules, and validate welding equipment performance.
WSI provides laboratory testing for spot welding, projection welding, capacitor discharge welding, MFDC welding, seam welding, and other resistance welding applications. Testing can include weld schedule development, weld lobe studies, push-out testing, tensile testing, electrode endurance testing, process monitoring and prototype welding.
What Is a Resistance Welding Laboratory?
A resistance welding laboratory is a controlled testing environment used to develop, evaluate and validate resistance welding processes before or during production. Testing can help determine material weldability, establish welding parameters, analyze weld failures, verify weld strength and evaluate welding equipment performance.
Why Use WSI’s Resistance Welding Laboratory?
- Develop welding parameters before production launch
- Determine whether a material or part is suitable for resistance welding
- Troubleshoot inconsistent or failed production welds
- Establish weld schedules and process windows
- Evaluate projection welded fasteners
- Compare AC, MFDC and capacitor discharge welding processes
- Validate equipment and process performance
- Test prototype parts before purchasing production equipment
- Document testing results and recommendations
Resistance Welding Lab Services
- Application / process evaluation and recommendations
- Suitability testing for resistance welding
- Weld failure analysis
- Weld schedule development
- Weld lobe analysis / design of experiment (DoE)
- Electrode endurance testing
- Projection weld fastener evaluation and testing
- Resistance welding training (rocker arm spot welders, press type welders, capacitor discharge welding, spot welding guns, benchtop welders, seam welders, door welders, XY welders, turntable welders multi-gun welders)
- Seminars (bring your parts and weld them in our lab.)
- Material weldability
- Process evaluation
- Metallurgical evaluation
- Equipment performance and recommendations
- Secondary weld current and micro-ohm-meter and benchmarking
- Calibration services (force gauges, weld checkers, weld current analyzers, torque wrenches, tensile testers)
- Weld coupons
- Prototype welding
* Welding lab services includes complete documentation
VIDEO - Projection Welding of Fasteners
Lab Welders | Process Verification | Miscellaneous Equipment
Following is a list of welders, process verification and miscellaneous equipment currently in our advanced resistance welding lab.
LAB WELDERS:
- WSI EconoPress, ECP1-18-AC-1-200-1-2430×4-480/60; Miyachi STA-100 Control; 200 KVA AC Transformer; Force 2,430 lbs @ 100 PSI
- WSI Size 1 MFDC, WSI-W1-12-DC-250-6×4-480/60-150; Miyachi IS-800 Advanced Inverter; 250 KVA MFDC Transformer; Force 2,800 lbs @ 100 PSI
- WSI Size 2 Fast Rise Time, WSI-W2-18-DC-225-8×4-480/60-400; Miyachi ISA-2000 Inverter; 225 KVA Fast Rise Time MFDC Transformer; Force 5,000 lbs @ 100 PSI
- WSI Size 2 CD, WSI-W2-18-CD-12-8×4-480/60-60; Miyachi P12000 Capacitor Bank; 12J Transformer; Force 5,000 lbs @ 100 PSI
- Tecna Portable Gun, 7902; Integrated Heat and Time Dials, Hand Pressure
- Taylor Winfield Bench Welder; Miyachi IPB-5000 Inverter; 17 KVA MFDC Transformer, Force 300 lbs @ 100 PSI
PROCESS VERIFICATION EQUIPMENT:
- Miyachi MM-315 Weld Checker with Current Monitoring
- Miyachi MM-370 Weld Checker with Current, Voltage, Displacement, Force Monitoring and Printer
- Miyachi MM-380 Weld Checker with Current, Voltage and Force Monitoring
- Miyachi MM-400 Weld Checker with Current, Voltage, Displacement, Force Monitoring and Printer
- Miyachi Screen Capture Software
- Miyachi ADAM (Advance Data Analysis Module), Microsoft Windows Based with Current, Voltage, Displacement, Gas Flow, Force Monitoring and Printer
- TECNA 1600/RS232 Weld Checker with Current and Force Monitoring
- TECNA 1700D Weld Checker with Current, Voltage and Force Monitoring
- Dengensha WS-80 Weld Checker with Current, Voltage, and Printer
- Welding Technologies DFI-101 Force Gauge, 0-4500 Pound Range
- Welding Technologies DFI-102 Force Gauge, 0-9000 Pound Range
- Welding Technologies DFI-102-Flex Force Gauge, 0-9000 Pound Range
- Miyachi Weld Through Force Gauge, MA-770A, 0-1100 Pound Range
- Miyachi Weld Through Force Gauge, MA-771A, 0-2100 Pound Range
- Snap-On ATECH3FR250B Torque Wrench, 12.5-250 ft-lb Range
- Ono-Sokki GS-1830A Glass Displacement Sensor, 30mm Range, 0.0005″ Resolution
- Mitutoyo 542-162 Linear Displacement Sensor, 25mm range, 0.0003″ Resolution
- WSI 100630 Standard Push-Out Tester, 0-9000 Pound Range
- WSI 100630-HD “C” Frame Push-Out Tester, 0-4500 pound Range
- Detroit Testing Machine Co Tensile Strength Tester
- Amprobe AMC-3 Meg-Ohm Tester
- Ryobi IR-002 Infrared Thermometer
- Slow Motion Camera
- Hi-Definition Camera
MISCELLANEOUS EQUIPMENT:
- Atlas Copco Air Compressor, 15 HP
- Schrieber 500AC Water Chiller, 5 Ton
- Tow Motor, 10K Capacity
- Pallet Jack, 5K Capacity
- Machine Room Mill and Lathe Capabilities
Industries Served
- Aerospace
- Automotive
- Appliance
- Electronic and electrical equipment
- Fabricated metal products
- Industrial machinery
- Oil and gas power generation
- Primary metals and metal processing
- Transportation
- and more
Frequently Asked Questions (FAQ) - WSI Resistance Weld Lab
What testing can WSI perform on resistance welds?
WSI can perform weld schedule development, weld lobe studies, push-out testing, tensile testing, weld failure analysis, metallurgical evaluation, electrode endurance testing, process monitoring, prototype welding and other resistance welding validation services.
Can WSI test my parts before I purchase a resistance welder?
Yes. WSI can evaluate customer parts and materials, develop welding parameters, test prototype welds and help determine the appropriate resistance welding process and equipment before production equipment is selected.
Can WSI develop a resistance welding schedule?
Yes. WSI’s welding laboratory can develop and document welding parameters and process windows for spot, projection, MFDC, capacitor discharge, seam and other resistance welding applications.
Can WSI perform weld failure analysis?
Yes. WSI can evaluate failed or inconsistent resistance welds to help identify problems involving welding parameters, materials, electrodes, force, current, equipment performance, and other process variables.
Can I send parts to WSI for weld testing?
Yes. Customers can work with WSI’s resistance welding laboratory to evaluate parts, materials, fasteners, and prototype welding applications. Contact WSI to discuss the application and testing requirements.
Need Help Developing or Troubleshooting a Resistance Welding Process?
Send WSI your parts, materials, or application requirements. Our resistance welding laboratory can help evaluate weldability, develop welding parameters, analyze weld failures, test prototype parts, and validate your welding process before production.
Contact Weld Systems Integrators
