In general, CD weld feasibility studies follow these steps:

1. PECo will evaluate your parts and specifications and compare them to our records of similar developments

2. PECo will choose the appropriate weld projection for your parts based on material, hardness and conductivity of the weld pair

3. Initial weld current is selected based on the volume of the projection

4. Initial weld force is selected based on the chosen weld current

5. If multiple pulses are required due to the part’s Carbon content, the energy used in subsequent pulses is chosen to match the weld energy

6. Weld is made using simple electrodes

7. Weld results are evaluated, adjustments are made, and weld tests are repeated until the desired output is achieved or it is determined that part modifications are required before the preferred result can be achieved. Results are evaluated based on the following:

   • If weld upset is not within limits, energy and force are adjusted in equal amounts and the next assembly is welded

   • Once the weld upset is within limits, destructive test failure mode evaluation is completed and if necessary, weld force is adjusted and next assembly is welded

   • Once weld upset and weld force are set, the temper current of any multiple pulses is adjusted based on the results of the destructive test. Tests are rerun as adjustments are made.

8. Final results are reported to you

At this point other modifications to the welding process may still be required including changes in material, alterations in the fixture, or modifications to the assembled parts. These modifications can be addressed in a PECo weld development study.