Residual Stress Measurements in Side Bonded Resistance Welds

Resistance upset welding is used to attach small diameter machined tubes to small gas vessels. Recently there has been interest in determining the residual stresses caused by this attachment method. A test program was initiated to determine the residual stresses present due to welding using the nominal weld parameters and varying the interference between the foot and the counter bore. In this paper, the residual stress measurement technique is described, the welding conditions are provided, and the measured residual stresses due to welding at the nominal conditions are presented.