How do you prevent discoloration in two 1.2 mm (0.047”) plates tack welded for a subsequent braze joint?

This is the description of a typical cosmetic weld where one surface must be preserved as is. All heat and distortion must come from the other side, we will call it the back side. To do this a large “FLAT” faced RWMA “C” electrode is used on the good side. On the back side an RWMA “A” or pointed nose or in this specific case one with a face of 1.5 mm (0.060”).

The weld schedule should be designed to generate the heat from the back side and stop as the weld nugget just begins to grow into the top sheet. This will not be the best weld that could be produced. It will be a tack weld just good enough to hold the part together until the braze is made.

If discoloration is an issue water misting cooling, a gas shield or any other means could be used to prevent heat or oxidation on the one side.

                  Cosmetic Weld Nugget No electrodes


Reference: RWMA - Resistance Welding Manual 4th Edition

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