Abstract
At present, no satisfactory nondestructive test is known which can be practically applied in the shop to detect a weak percussive-welded connection. Also, the breaking strengths within a population of percussive welds are distributed in such a way that large sample sizes are needed to determine, with reasonable confidence, if the population contains an excessive number of weak welds. Monitoring the duration of the welding arc and the approach speed of the wire, for each weld as it is made, has been found to provide an effective control of the process. An analysis of the process yields necessary conditions which the arc duration and wire speed must satisfy. Test data are presented which confirm the necessity of these conditions, and show that when they are satisfied, percussive-welded connections can meet quality objectives.
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