Resistance Welding

Principle of Resistance Welding

• Definition: Resistance welding is a liquid state welding method where metal-to-metal
joints are formed within a molten state.
• Resistance welding is a fascinating process used to create strong weld joints by generating
heat through electric resistance.
• Working Principle:
o Heat is generated due to electric resistance.
o The same principle applies within the electric coil.
o Heat softens the edge metal, creating a strong weld joint with fusion.
o No flux, filler material, or shielding gases required.

Equipment for Resistance Welding

1. Power Source:
o DC power supply with reverse polarity (positive electrode).
o Ensures maximum heat at the tool side for proper melting of the filler metal.
2. Electrical Circuit: Provides the necessary current for welding.
3. Contactors & Timers: Control the welding process.
4. Mechanical Systems: Hold and position the workpieces during welding..

. Operation of Resistance Welding Limitations of Resistance Welding

• Continuous Process: Electrode wire fed continuously. 1. Tungsten Contamination:
• Position: Suitable for horizontal, vertical, and overhead welding. o Can make welds hard and brittle.
• Current Range: Typically 100 A to 600 A. o Proper control of electrode material is crucial.
• Applications: 2. Shield Contamination:
o Automotive industry. o Must control shielding gases to prevent contamination.
o Structural steel fabrication. o Reactive gases can affect weld quality.
o Repair work.
 1. Types of Resistance Welding:
1. Principle of Resistance Welding: o Spot Welding:
o All resistance welding techniques (such as spot welding, seam welding, projection ▪ Simplest type of resistance welding.
welding, and flash butt welding) operate on the same fundamental principle: heat ▪ Workpieces are held together under pressure using an anvil face.
generation due to electric resistance. ▪ Copper electrodes make contact with the workpiece, and current flows
o When an electric current passes through a material with resistance, it produces heat. through them.
This concept is akin to how an electric coil works. ▪ Local heat generation occurs due to the workpiece material’s resistance.
o The amount of heat generated depends on factors like material resistance, surface ▪ The interface surfaces melt, forming a circular nugget.
conditions, current intensity, and duration. ▪ Nugget size depends on electrode diameter (typically 4-7 mm).
o The heat melts the interface metal, creating a weld joint without the need for filler o Seam Welding:
material, flux, or shielding gases. ▪ Used for continuous welding along a seam.
▪ Similar to spot welding but with moving electrodes.
▪ Creates a continuous weld along the seam.
1. Main Equipment Required for Resistance Welding: o Projection Welding:
▪ Used for joining parts with raised features (projections).
o Electrical Circuit: Provides the necessary current for welding.
▪ Projections concentrate heat at specific points for welding.
o Contactors & Timers: Control the welding process.
o Mechanical Systems: Hold and position the workpieces during welding. o Flash Butt Welding:
▪ Involves butt welding two workpieces end-to-end.
2. Advantages and Disadvantages:
▪ Intense heat is generated at the joint, causing fusion.
o Advantages:
▪ Simplicity: No need for expert labor.
▪ No filler material or shielding gases required.
▪ Suitable for a wide range of material thicknesses (from 0.1 mm to 20 mm).
o Disadvantages:
▪ High equipment cost.
▪ Limited material thickness applicability.
 Resistance Spot Welding (RSW)

Principle of Resistance Spot Welding

• Definition: Resistance spot welding is a widely used welding process that joins two or Operation of Resistance Spot Welding
more metal sheets by applying pressure and heat to localized points. • Process:
• Working Principle: 1. Workpieces are clamped between the electrodes.
o Two copper electrodes apply pressure to the workpieces. 2. Current flows through the contact points, generating heat.
o An electric current passes through the electrodes, creating resistance at the contact 3. The heat melts the metal, creating a weld nugget.
points. 4. Pressure is maintained until solidification occurs.
o Heat is generated due to this resistance, melting the metal at the joint.
o The molten metal solidifies, forming a weld nugget. . Applications of Resistance Spot Welding
• Automotive Industry:
o Used for joining car body panels, frames, and components.
Equipment for Resistance Spot Welding • Sheet Metal Fabrication:
1. Spot Welding Machine: o Joins thin metal sheets in various industries.
o Consists of a power supply, electrode holders, and copper electrodes. • Appliances and Electronics:
o Provides the necessary current and pressure for welding. o Welding of refrigerator components, electrical enclosures, etc.
2. Electrodes:
o Copper alloy electrodes transmit current to the workpieces.
o Shaped to concentrate heat at the weld spot.
3. Control System:
o Monitors current, time, and pressure during welding.

Limitations of Resistance Spot Welding

1. Material Thickness:
o Suitable for thin to medium thickness
materials (up to 3 mm).
o Not ideal for thick sections.
2. Limited Joint Configuration:
o Best for lap joints and T-joints.
o Not suitable for complex geometries.
 Resistance Seam Welding (RSW)
Principle of Resistance Seam Welding
• Definition: Resistance seam welding is a variation of spot welding where a series of
overlapping nuggets are produced instead of a single spot weld.
• Process:
o Workpieces are clamped between copper electrodes.
o Electric current passes through the contact points, generating heat.
o Heat melts the metal, creating a continuous weld along the seam.
o Pressure is maintained until solidification occurs.

Equipment for Resistance Seam Welding

1. Seam Welding Machine:
o Consists of a power supply, electrode holders, and copper wheels.
o Provides necessary current and pressure for welding.
2. Electrodes:
o Copper alloy wheels transmit current to the workpieces.
o Shaped to concentrate heat along the seam.
3. Control System:
o Monitors current, time, and pressure during welding.
Operation of Resistance Seam Welding
• Uphill Welding Process:
o Plates to be welded are held vertically.
o Weld joints are made in a vertical direction.
o Suitable for both single-pass and multipass welding. Applications of Resistance Seam Welding
• Automotive Industry:
Limitations of Resistance Seam Welding
o Used for joining car body panels, fuel tanks, and exhaust
1. Material Thickness:
systems.
o Suitable for thin to medium thickness materials (up to 3 mm).
• Sheet Metal Fabrication:
o Not ideal for thick sections.
o Joins thin metal sheets in various industries.
2. Limited Joint Configuration:
• Pipe Manufacturing:
o Best for lap joints and T-joints.
o Creates longitudinal welds in pipes and tubes.
o Not suitable for complex geometries.
 projection welding,
1. Principle:
o Projection welding produces coalescence by the heat generated from the resistance
to the flow of welding current.
o Welds are localized at predetermined points by projections, embossments, or
intersections.
o It uses the same equipment as spot welding, but with flat-ended electrodes larger in
diameter.

1. Working:
o Surface Preparation: Projections (small deformations) are made on the weld areas.
o Welding Process:
▪ Current flows through the two parts to be welded.
▪ The projected points are the main contact area.
▪ When a point touches the metal, a weld nugget starts.
▪ The weld points reach the plastic state, and electrode force finishes the weld.
▪ Cycle time is similar to spot welding.
▪ The finished weld resembles spot welding with small indentations from
projections. 1. Advantages:
1. Applications: o Simplicity: Easy to join several welding points simultaneously.
o Increased Output: Multiple welds done at once.
o Automotive Industry: Used for welding components like brackets, clips, and
o Longer Electrode Life: Low current density and pressure.
fasteners.
o Good Appearance: Surface remains unindented by electrodes.
o Electrical and Electronic Industry: Joins terminals, connectors, and small
Automatic Location: Welds are automatically located by projection positions.
electrical components.
o Stud Welding: Also utilized for car bodies.
1. Disadvantages:
o Weaker Joints: Not as strong as some other welding methods.
o Limited Load-Bearing: May not withstand heavy loads.
o Safety Concerns: Requires careful handling due to projections.