Spot welding is a mechanical bonding method which lends itself to high production volumes. An example of this is the motor car industries use of this bonding method. A typical car requires between 3,000 and 5,000 spot welds.
點焊是一種機械焊合方法，這種特性使得它具有生產率高的特點。使用該焊合方法的一個典型例子是汽車產業(yè)。通常一輛轎車需要3000到5000個焊點。
A simplified diagram of the welding process and its parameters is illustrated below.
該焊接方法的一個簡化的示意圖和參數(shù)如下所示。 tireweb.cn www.dingzhi17.com
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Type of material
材料種類
Type of coating (if applicable)
涂層種類（如果使用的話）
Number of sheets (plates)
鈑金數(shù)量（層數(shù)）
Sheet thickness
鈑金厚度
Nugget diameter (usually given by the formula d = 4x(square root of t), where t is the thickness of the thinnest plate in the combination)
融核直徑（通常由公式d=4x（t的平方根)確定），該處t為在連接的鈑金中*薄鈑金的厚度。
No weld 無焊點
Small nugget 小焊核
Thin nugget 薄焊
Stick weld 粘接
Flaws (porosity) in nugget 焊核中有缺陷（孔洞）
Burnt spot 過燒
Direct cost savings 節(jié)省直接成本
nReduce inventory loss 減少存貨損失
nReduce inspection time 降低檢測時間
nImprove testing safety 提高檢測安全性
Indirect cost savings 節(jié)省間接成本
nImprove reliability of welds 提高焊接的可靠性
nImprove reliability of welding process 提高焊接制程的可靠性
Documentation – comply with ISO 9000 / EN Norm 文件－符合ISO 9000/EN規(guī)范
The current method is to test the spot weld using the chisel and hammer method accompanied by visual inspection. This method takes time and the part often requires rework or is often discarded.
當前的檢驗點焊的檢測方法是采用鑿子或錘擊然后目視檢測。這種方法花費時間而且部件需要被重新加工或被丟棄。
Testing to destruction of car sub-assemblies and/or complete car bodies. The costs associated with this method in three of the United State’s biggest car manufacturing plants are estimated to $400 to $600 million per year through loss of value-added inventory.
檢測時要破壞汽車零部件和/或整車車體。這種方法的造成的相關成本在美國*大的三個汽車公司中估計達到4億到6億美元。
Other non-destructive testing methods have been tried for inspecting spot welds, but most of these fail to reliably detect “stick” or “cladding” type spot weld defects. These methods include: thermal/infrared, electrical conductivity, x-ray and eddy-current methods.
其它的無損檢測方法也曾被用于檢測點焊，但它們中的大多數(shù)不能可靠檢測如“粘結”或“覆層”類的點焊缺陷。這些方法包括：熱/紅外，電導率，X射線和渦流方法。
The ultrasonic method is fast, “stick” welds can be detected and automated classification allows to inspect production line spot welds in an efficient and reliable manner.
超聲方法是快速的，“粘結”焊點可以被檢測和自動分類，所以可以對點焊生產線進行高效和可靠的檢測
If 50% of the components including spot welds could be tested non-destructively and then sold, the potential cost savings associated with the previous example could be approximately $200 to $300 million per year.
如果50％的部件（包括點焊）可以使用非破壞性方法檢測，然后出售，在上例中每年可以節(jié)省的成本可達2億到3億美元每年。
Reducing by 10% the number of redundant welds in a car may yield savings of $400 to $600 million/year.
每輛汽車減少10％的多余焊點每年可以節(jié)省4億到6億美元。
The effective diameter of the UT beam should be equal to the diameter of the nugget
超聲波聲束的有效直徑應該等于融核的直徑。
The nugget diameter can be determined according to the thinnest plate thickness as follows:
融核點的直徑可以根據(jù)*薄板的厚度計算如下：
D = 4 x d10.5
The transducer frequency required for a given plate thickness d1 can be approximated by:
根據(jù)給定鈑金厚度d1可以估計探頭的頻率 > 3c/d1
Spot welding is a mechanical bonding method which lends itself to high production volumes. An example of this is the motor car industries use of this bonding method. A typical car requires between 3,000 and 5,000 spot welds.點焊是一種機械焊合方法，這種特性使得它具有生產率高的特點。使用該焊合方法的一個典型例子是汽車產業(yè)。通常一輛轎車需要3000到5000個焊點。A simplified diagram of the welding process and its parameters is illustrated below.該焊接方法的一個簡化的示意圖和參數(shù)如下所示。 tireweb.cn www.dingzhi17.com
No weld 無焊點Small nugget 小焊核Thin nugget 薄焊Stick weld 粘接Flaws (porosity) in nugget 焊核中有缺陷（孔洞）Burnt spot 過燒Direct cost savings 節(jié)省直接成本nReduce inventory loss 減少存貨損失nReduce inspection time 降低檢測時間nImprove testing safety 提高檢測安全性Indirect cost savings 節(jié)省間接成本nImprove reliability of welds 提高焊接的可靠性nImprove reliability of welding process 提高焊接制程的可靠性Documentation – comply with ISO 9000 / EN Norm 文件－符合ISO 9000/EN規(guī)范The current method is to test the spot weld using the chisel and hammer method accompanied by visual inspection. This method takes time and the part often requires rework or is often discarded.當前的檢驗點焊的檢測方法是采用鑿子或錘擊然后目視檢測。這種方法花費時間而且部件需要被重新加工或被丟棄。Testing to destruction of car sub-assemblies and/or complete car bodies. The costs associated with this method in three of the United State’s biggest car manufacturing plants are estimated to $400 to $600 million per year through loss of value-added inventory.檢測時要破壞汽車零部件和/或整車車體。這種方法的造成的相關成本在美國*大的三個汽車公司中估計達到4億到6億美元。Other non-destructive testing methods have been tried for inspecting spot welds, but most of these fail to reliably detect “stick” or “cladding” type spot weld defects. These methods include: thermal/infrared, electrical conductivity, x-ray and eddy-current methods.其它的無損檢測方法也曾被用于檢測點焊，但它們中的大多數(shù)不能可靠檢測如“粘結”或“覆層”類的點焊缺陷。這些方法包括：熱/紅外，電導率，X射線和渦流方法。The ultrasonic method is fast, “stick” welds can be detected and automated classification allows to inspect production line spot welds in an efficient and reliable manner.超聲方法是快速的，“粘結”焊點可以被檢測和自動分類，所以可以對點焊生產線進行高效和可靠的檢測If 50% of the components including spot welds could be tested non-destructively and then sold, the potential cost savings associated with the previous example could be approximately $200 to $300 million per year.如果50％的部件（包括點焊）可以使用非破壞性方法檢測，然后出售，在上例中每年可以節(jié)省的成本可達2億到3億美元每年。Reducing by 10% the number of redundant welds in a car may yield savings of $400 to $600 million/year.每輛汽車減少10％的多余焊點每年可以節(jié)省4億到6億美元。The effective diameter of the UT beam should be equal to the diameter of the nugget超聲波聲束的有效直徑應該等于融核的直徑。The nugget diameter can be determined according to the thinnest plate thickness as follows:融核點的直徑可以根據(jù)*薄板的厚度計算如下：D = 4 x d10.5The transducer frequency required for a given plate thickness d1 can be approximated by:
