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Resistance Welding

Resistance Welding. The resistance of metal to the localized flow of current produces heat Process variables Current Time Force Spot and seam welding. Spot welding. electrode. electrode. Electrodes. Electrode tips wear during service, causing nugget size to decrease

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Resistance Welding

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  1. Resistance Welding • The resistance of metal to the localized flow of current produces heat • Process variables • Current • Time • Force • Spot and seam welding Spot welding

  2. electrode electrode

  3. Electrodes • Electrode tips wear during service, causing nugget size to decrease • Zinc-coating on steel alloys with copper electrodes to form brass • Copper base materials, divided into classes Truncated cone Dome Pointed

  4. Operating Window - Lobe Curve Constant electrode force Acceptable nugget size Time (cycles of current) Nugget too small Expulsion Current (1000’s of amperes)

  5. Roll spot weld Overlapping seam weld Continuous seam weld

  6. Resistance Welding Advantages • High speed, < 0.1 seconds in automotive spot welds • Excellent for sheet metal applications, < ¼-inch • No filler metal

  7. Process Disadvantages and Limitations • Higher equipment costs than arc welding • Power line demands • Nondestructive testing • Low tensile and fatigue strength • Not portable • Electrode wear • Lap joint requires additional metal

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