Characterization of Appendage Weld Quality by On Line Monitoring of Electrical Parameters

Abstract

Resistance projection welding of zirconium alloy appendages is one of the most critical processes in the PHWR fuel fabrication. Appendages like Spacers and Bearing pads having multi projections are joined to the fuel sheath using capacitor discharge power source. Variations in the projection sizes, weld parameters and cleanliness of the work pieces have significant effect on the weld quality, in addition to material properties like hardness, tensile strength and surface finish. Defects like metal expulsion and weak welds are occasionally observed in appendage welding process, which need to be identified and segregated. Though numerous off-line inspection methods are available for the weld quality evaluation, online monitoring of weld quality is essential for identifying defective welds. For this purpose, various monitoring techniques like acoustic emission, analyzing derived electrical parameters and weld upset/deformation measurements are employed. The derived electrical parameters like A2 -Sec and Ohm-Sec can also be monitored. The present paper highlights development of suitable acceptance criteria for the monitoring technique by employing derived electrical parameters covering a wide range of weld variables like watt-sec and squeeze force. Excellent correlation could be achieved in identifying the weak welds and weld expulsion defects in mass production.