Computation-Experimental Estimation of the Resistance of the Welding Zone during Electrocontact Welding with an Intermediate Layer

Abstract—The results of a computation-experimental estimation of the resistance of the welding zone during electrocontact welding (ECW) of a metal tape through an intermediate layer are presented. Characteristic resistance zones are determined, and the stages of joint formation and the state of resistance during ECW are considered. The influence of the compressive force on the resistance of the joint zone, the welding current, and the heat released in the welding zone at each contact site is analyzed, and dependences for calculating these quantities are presented with allowance for shunting and heating of the materials to be joined. The optimum compressive forces at each ECW stage are determined. Recommendations are given for adjusting the welding current during transitions to the next welding stages.