This document discusses reducing splatters in intercell welding of lead acid batteries. Splatters are unwanted metal particles expelled during resistance welding that reduce quality. The researcher analyzed the problem using tools like fishbone diagrams and identified key causes as insufficient electrode contact area, tip gap variation, and flag misalignment. Their proposed solutions were increasing the electrode diameter to improve contact area, using a lock nut to control tip gap, and adding ribs to properly align flags. Testing showed these solutions reduced monthly splatter rates from over 4% to under 0.3%, improving productivity, quality, and savings.

1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 597
REDUCTION OF SPLATTERS IN INTERCELL WELDING OF A LEAD ACID
BATTERY
Boggiti Manikanta1, Shiva sankar2
1PG Scholar, Mechanical Engineering, Chadalawada Ramanamma Engineering College, Tirupati, A.P, India.
2Asst. Professor, Mechanical Engineering, Chadalawada Ramanamma Engineering College, Tirupati, A.P, India.
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Abstract - Splatters are the major lossesinresistance welding
process. Splatter or weld splash is the unwanted creation of
small metal particles that are expelled from the welding area
during the welding process. These small metalparticlescan be
airborne in the form of “hot sparks” or can solidify as small
“balls” or “filaments” that remain loosely attached to the
welding area. Excessive weld splash can be an indicator of a
weld joint filled with voids and cracks, which can propagate
with vibration and temperature cycling to create a future,
weld failure. In this paper, I am here to reduce the splatters by
varying the electrode geometry. In order to reduce these
losses, there was many people have studied and did many
researches. The researches may be did by varying the weld
parameters such as weld current, weld time, cool time,
pressure and squeeze time. By playing all these parameters
they might have reduced the splatters to some extent. But in
fact the amount of heat generated during welding process
plays a major role in production of splatters. Splatter losses
are mainly due high heat generated during the welding. So I
would like to concentrate on distribution of heat generated
during welding and control the splatters by increasing the
surface area of the electrodes.
Key Words: Splatters,Resistancewelding,Weld current,
Weld time, cool time, pressure and squeeze time,
Thermo electric process
1. INTRODUCTION
Resistance spot welding is a process in which coalescences
produced at two faying surfaces by heat generated at the
joint to form lap joint. Spot welding producessinglespotlike
welds, which are called nuggets. The heat is generated by
resistance to flow of current though the work piece.
Electrodes are located on both sides of the work piece in
which one is movable and other is fixed. The advantages of
spot welding include cost efficiency, good dimensional
accuracy and reliable production. Without large
deformation, it can be used for joining of several metallic
materials and sheets of different thicknesses together.
Heat generation in resistance welding is takes place by
heating phenomenon. The heat generated dependsuponthe
current, the time the current is passed and the resistance at
the interface. The resistance is a function of the resistivity
and surface condition of the parent material, the size, shape
and material of the electrodes and the pressure applied by
the electrodes.
Fig.1 Illustration of resistance welding process
Generally, amount of heat generated during resistance
welding process is given by the following formula:
Heat = I^2xRxT
Where
I - Weld current applied on work piece
R- Work piece electrical resistance in Ohms
T- Weld time in milli seconds
1.1 Literature Review
Literature review has been done for analyzing the process
parameters and their effect on the response variables of the
resistance welding. Gajanan S. Gaikwad[1], reviews on
various effects of process parameters on responsevariables.
Input parameters such as welding current, weld time,
electrode force and electrode geometry effects on the
response variables such astensilestrength,hardness,nugget
size. He used ANOVA and Taguchi has been most efficient
and powerful tool for optimization of resistance welding
response parameters which produce high quality parts
rapidly and low cost. A. G. Thakur, T. E. [2] says that the
amount of resistance at the interface of the work piece
depends on the heat transfer capabilities of the material,the
material’s electrical resistance, and the combined thickness
of the materials at the weld joint.

2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 598
M. Vural et al. [3] has done study on the fatigue strength of
resistance spot welded galvanized steel sheets and AISI 304
sheets. The results show that galvanized steel sheet
combination has the highest fatigue limit. The sheet
combination which has minimum fatigue limitisgalvanized-
AISI 304 sheet combination. D.S. Sahota [4]. The objective of
this work is to study the effect of parameters on resistance
spot weld of ASS316 material.
1.2 Inter cell Welding machine and operation
Fig -2: Schematic representation of Inter cell welding
operation in a battery
Two work pieces are joined together firmlybysqueezingthe
electrodes with the help of hydraulic pressure. Weld start
time and squeeze time plays a major role in weldingprocess.
Each connected joint cell gives 2V. There are totally 6 cells
are there. So totally 12V will be the battery output.
2. PROBLEM IDENTIFICATION
2.1 Sound weld in cell to cell welding
Fig -3: Internal weld structure of the cell
Sound weld structure should be as shown in Fig.3 after
destructive test.
2.2 Splatters in cell to cell welding
Fig -4: Defect joint in the battery i.e., splatter cell
2.3 Electrode wears out
Fig -5: Electrode condition after 40000 batteries welding
2.4 Impact of the problem:
1. Low Productivity
2. Battery life reduced
3. Low quality
4. Increasing scrap percentage
3 ANALYSES
3.1 4W1H technique
• WHAT
• Splatters in Inter cell welding operation
• WHEN
• While welding operation
• WHERE
• At weld nugget
• WHO
• Quality and productivity
• HOW
• By analyzing the problem and causes
3.2 Brain storming
 Hydraulic oil pressure
 Weld start time

3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 599
 Weld cool time
 High weld current
 Squeeze length
 Electrode Contacting area less
 Electrode wear out
 Less flag width
 Tip gap variation
 Improper alignment
 Container hole variation & flashes in hole
 Operator awareness
 Improper cooling of flags
 Material composition
3.3 Fish bone diagram
3.3.1 Machine
• Hydraulic pressure
• Weld start time
• Squeeze length
• Weld cool time
• Weld current
• Tip gap variation
3.3.2 Man
• Operator awareness
• Less trained
• Lack of skill and competency
3.3.3 Method
• Electrode contact area
• Insufficient cooling of electrodes
• Insufficient cooling of jaws
3.3.4 Material
• Material composition
• Electrode wear out
• Flag alignment disturbed
• Ribs not provided in container
• Less flag width
• Container hole diameter variation
• PPCP container flashes in holes
3.3.5 Majority causes
By using brainstorming technique we have identified the
vital few causes.
• Electrode Contacting area less
• Tip gap variation
• Flag alignment disturbed
3.3 WHY-WHY Analysis
Cause: 1- Electrode contacting area less
Cause: 2- Tip gap variation

4. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 600
Cause: 3- Flag aligned disturbing
3.4 Developing solutions
Table-1: Solutions identified
S.No Cause identified Solution implemented
1 Electrode Diameter
(contacting area) less
than the flag width
Electrode outer
diameter increased
2 Tip gap variation Hardened bolt used &
Lock nut provided
3 Flag alignment
disturbed
Ribs provided in
container to locate flags
3.3.1 Existing electrode geometry
Fig.6 Existing electrode drawing outline
3.3.2 Proposed electrode geometry
Fig.7 Propesed electrode drawing outline
3.4 Comparison between Existing and proposed
electrode
Fig.8 Pictorial represntation of electrode surface area
Existing electrode is having less contact withthework piece.
So heat distribution is not uniform as less surface are of the
electrode. Amount of heat dissipatedwill meltthejointatthe
time of welding leads to splatters. The proposed electrode is
having very good contact with the work piece. So heat
distribution is uniform and splatters are reduced at most
extent.

5. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 601
4 RESULTS AND DISCUSSIONS
4.1 Electrode outer diameter increased
4.2Hardened bolt used & Lock nut provided
4.2 Ribs provided in container to locate flags

6. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 602
4.4 Monthly battery production and scrap
Table-2: Month wise battery production and scrap
generated
Month Production Defects
(Splatters)
Percentage
May 12365 503 4.07
June 22172 662 2.99
July 24939 307 1.23
August 26354 186 0.70
September 31820 97 0.30
October 35528 134 0.38
November 28210 100 0.35
December 30435 86 0.28
January 31775 82 0.26
February 41843 110 0.26
4.5 Monthly rejection trend
Chart-1: Graphical represntation of prosuction Vs scrap
4.5 Intangible benefits
 Increased productivity
 Learned an effective problem solving
methodology & QC tools
 Ability to take up the new challenges
 Increased employee morale.
4.6 Tangible benefits
 Expected cost savings / annum
Battery scrap reduced from 503 no's to 110 no's
1 battery cost = Rs.5800
 Total cost savings = Rs.1.74 millions / annum
5 CONCLUSIONS
As we have seen here there is gradual reduction of splatters
from month to month. So it is concluded that proposed
electrode can bare the amount of heat generated during
welding process and that can reduce the splatters in major
extent. And finallytheseproposed electrodesareamendedin
the engineering product drawing.
REFERENCES
[1] Gajanan S. Gaikwad, Dr. K. H. Inamdar. (2016) A review
on effect of process parameters of resistance welding, Vol
No.4, Issue No.12.
[2] A. G. Thakur, T. E. Rao, M. S. Mukhedkar, and V. M.
Nandedkar, Application of Taguchi method for resistance
spot welding of galvanized steel, ARPN Journal of
Engineering and Applied Sciences, 5, 2010, 22-26.
[3] Vural M., Akkus A., and Eryurek B, Effect of weld nugget
diameter on the fatigue strength of the resistance welds
joints of different steel sheets”, Journal of Materials
Processing Technology, 176, 2002, 127-132.
[4] D.S. Sahota et al. study of effect of parameters on
resistance spot weld of ASS316 Mechanica Confab ISSN:
2320-2491