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Methods of weld testing and analysis are used to assure the quality and correctness of the weld after it is completed. This term generally refers to testing and analysis focused on the quality and strength of the weld but may refer to technological actions to check for the presence, position, and extent of welds.
In some applications wire sizes are specified as the cross sectional area of the wire, usually in mm 2. Advantages of this system include the ability to readily calculate the physical dimensions or weight of wire, ability to take account of non-circular wire, and ease of calculation of electrical properties.
However, AWG is dissimilar to IEC 60228, the metric wire-size standard used in most parts of the world, based directly on the wire cross-section area (in square millimetres, mm 2). The AWG tables are for a single, solid and round conductor. The AWG of a stranded wire is determined by the cross-sectional area of the equivalent solid conductor.
The formula to calculate the area in circular mil for any given AWG (American Wire Gauge) size is as follows.represents the area of number AWG. = (() /) For example, a number 12 gauge wire would use =:
For uninsulated cables (typically used in outdoor overhead installations), the tensile strength of the cable (as affected by temperature) is normally the limiting material property. The Neher–McGrath method is the electrical industry standard for calculating cable ampacity, most often employed via lookup in tables of precomputed results for ...
In either type of wire bonding, the wire is attached at both ends using a combination of downward pressure, ultrasonic energy, and in some cases heat, to make a weld. Heat is used to make the metal softer. The correct combination of temperature and ultrasonic energy is used in order to maximize the reliability and strength of a wire bond.
The voltage needed for welding depends on the resistance of the material to be welded, the sheet thickness and desired size of the nugget. When welding a common combination like 1.0 + 1.0 mm sheet steel, the voltage between the electrodes is only about 1.5 V at the start of the weld but can fall as low as 1 V at the end of the weld.
Undercutting is when the weld reduces the base metal's cross-sectional thickness and reduces the strength of the weld and workpieces. One reason for this type of defect is excessive current, which causes the edges of the joint to melt and drain into the weld, thus leaving a drain-like impression along the length of the weld.