Solid-state and fusion resistance spot welding of TD-NiCr sheet

By using specially processed TD-NiCr sheet in both 0.4-mm (0.015-in.) and 1.6-mm (0.062-in.) thicknesses and carefully selected welding procedures, solid state resistance spot welds were produced which, after postheating at 1200 C, were indistinguishable from the parent material. Stress-rupture shear tests of single-spot lap joints in 0.4-mm (0.015-in.) thick sheet showed that these welds were as strong as the parent material. Similar results were obtained in tensile-shear tests at room temperature and 1100 C and in fatigue tests. Conventional fusion spot welds in commercial sheet were unsatisfactory because of poor stress-rupture shear properties resulting from metallurgical damage to the parent material.