Nugget Formation In Resistance Fusion Welds

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Discuss nugget formation including size and shape as a function of welding parameters on the resistance welding nugget. A longer pulse will form a flatter and wider nugget, while a shorter pulse of higher energy will form a narrower but taller nugget. Excessive growth of the wide nugget will lead to expulsion. Excessive growth of the taller nugget will lead to indentation, electrode sticking, surface porosity, and corrosion.

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