Selection of parameters for flash butt welding on mild steel brake tension rods

Among the various joining technique used in the industries, welding is quite common and popular. However, at times it is a very complex process in which a large number of variables are involved governing the quality of weld and the resulting properties. In certain applications, like rolling stocks/rail coaches, the quality of the weld and mechanical properties of the joint are of paramount importance considering the fact that it may be a joint affecting the safety aspects. Keeping this in mind, experiments have been carried out to optimize the process parameters of flash butt welding of brake tension rods of a rail coach/rolling stock. In the present work only the major process parameters of flash butt welding of mild steel brake tension rod namely rate of current flow, heating time, flashing way, initial distance between the jaws was studied and effort has been made to optimize the same. The process parameters, once optimized, can reduce the rejection considerably as well as minimize the dependence upon operator’s skill.