Electron Beam Weld Schedule Development

Welding parameters are typically chosen from experience, records, or performing a parametric study. If this information is unavailable, the following graph can provide a starting point for weld schedule development.

To use this graph:

Print the graph.
Find the desired penetration level.
Draw a vertical line from this point until it intersects with the power curve of the desired material.
Draw a horizontal line from this point until it intersects with the heat input axis.
Use 50kV accelerating voltage and welding speed and current to achieve the required heat input.

Resistance Welding

Suggested Settings for Welding
Low Carbon Steel
(Based on 1010)

Material In. Thick	E Tip In. Dia.	Class	Electrode Weld Force, lbs.	Amps	Cycles of CO	HT	Impulses	Min. Avg. Tensile lbs. Shear	Min. Avg. Spot Dia.
0.010	0.12	2	100	3,200	1	2	1	140	0.060
0.021	0.19	2	200	5,600	1	3	1	345	0.100
0.031	0.19	2	300	7,500	1	4	1	695	0.140
0.040	0.25	2	450	9,000	1	5	1	1,000	0.160
0.050	0.25	2	600	11,000	2	5	2	1,475	0.180
0.062	0.25	2	800	12,200	2	5	3	2,170	0.200
0.078	0.31	2	1,100	13,700	2	5	3	2,920	0.220
0.094	0.31	2	1,450	17,000	2	5	4	3,710	0.245
0.109	0.38	2	1,800	19,000	2	5	5	4,532	0.260
0.125	0.38	2	2,200	21,000	2	5	6	5,310	0.280
0.156	0.44	2	3,000	24,200	2	5	9	7,300	0.320
0.187	0.50	2	4,000	28,300	2	5	12	11,500	0.350
0.250	0.62	2	6,700	35,300	2	5	19	18,600	0.385

Suggested Settings for Spot Welding
Stainless Steel
(Based on Aisi-304)

Material In. Thick	E Tip In. Dia.	Class	Electrode Force, lbs.	Amps	Cycles of CO	Cycles of HT	Impulses	Min. Avg. Tensile lbs. Shear	Min. Avg. Spot Dia.
0.016	0.12	2	300	3,900	1	*1	2	260	0.085
0.020	0.16	2	450	4,300	1	1	2	345	0.100
0.025	0.16	2	520	4,950	1	2	2	495	0.120
0.032	0.19	2	750	5,750	1	3	2	695	0.140
0.040	0.19	2	900	6,600	1	4	2	1,000	0.160
0.051	0.25	2	1,200	8,150	2	5	2	1,475	0.180
0.062	0.25	2	1,500	9,500	2	5	2	2,170	0.200
0.078	0.25	2	1,700	10,200	2	5	3	2,920	0.220
0.081	0.31	2	1,900	11,400	2	5	3	3,025	0.225
0.091	0.31	2	2,500	13,000	2	5	4	3,560	0.240
0.109	0.38	2	3,300	14,700	2	5	5	4,532	0.260
0.125	0.38	2	4,000	16,200	2	5	6	5,310	0.280
* 1 Cycle, 1 Phase

Suggested Settings for Spot Welding
Aluminum Alloys
(Based on 2014-T6 & 2024-T3)

Material
In.
Thick F
Tip
In.
Rad. Class Electrode
Force,
lbs.
Weld Electrode
Force,
lbs.
Forge Amps Cycles
of CO Cycles
of HT Cycles
of CD Impulses Min.
Avg.
Tensile
lbs. Shear Min.
Avg.
Spot Dia.

0.020 3 1 500 0 26,000 1 0.5 0 1 175 0.100

0.025 3 1 500 1,500 34,000 1 1 3 1 235 0.120

0.032 4 1 700 1,800 36,000 1 1 4 1 325 0.140

0.040 4 1 800 2,000 42,000 1 1 4 1 435 0.160

0.051 4 1 900 2,300 46,000 1 1 5 1 585 0.180

0.064 6 1 1,300 3,000 54,000 1 2 5 1 840 0.200

0.072 6 1 1,600 3,600 61,000 1 2 6 1 1,035 0.210

0.081 6 1 2,000 4,300 65,000 1 3 6 1 1,285 0.225

0.091 6 1 2,400 5,300 75,000 1 3 8 1 1,570 0.240

0.102 8 1 2,800 6,800 85,000 1 3 8 1 1,925 0.250

0.125 8 1 4,000 9,000 100,000 1 4 10 1 2,650 0.280