CHAPTER 3: OPERATING INSTRUCTIONS
PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
3-22
990-083
Evaluate Results
Figure 3-5 illustrates a typical Weld Strength Profile. Curve C shows the highest pull strengths but the lowest
tolerance to changes in weld current. Curve B shows a small reduction in strength but considerably more tolerance
to changes in weld current. Weld energy/current will vary as a result of material variations and electrode wear.
Curve B is preferred since it shows more tolerance to changes in weld energy and has nearly the same bond
strength as Curve C.
A comparison of weld schedules for several different applications might show that they could be consolidated into
one or two weld schedules. This would have obvious manufacturing advantages.
Electrode Maintenance
Depending on use, periodic tip resurfacing is required to remove oxides and welding debris from electrodes.
Select [NO WELD]. On air actuated weld heads, reduce the air pressure to a value just sufficient to lower the
upper electrode arm.
Cleaning of electrodes on production line should be limited to use of #400-600 grit electrode polishing disks. For
less critical applications, a file can be used to clean a badly damaged tip. However, polishing disks should then be
used to ensure that the electrode faces are smooth. If this is not done, the rough surface of the electrode face will
have a tendency to stick to the workpiece.
Place the polishing disks between the electrodes and actuate the footpedal or footswitch to bring the electrodes into
light contact with the polishing disk. Move the polishing disk in a rotary motion. Wipe electrode tips so that they
are clean.
