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    Definition of Resistance Welding

    Uploaded by

    Mitul patel
    Resistance welding is a fusion welding process that uses heat generated by resistance of workpieces to electrical current flowing through them to join metals. It applies force before, during, and after current application to prevent arcing. Melting occurs at the faying surfaces. Common types include spot, seam, projection, upset, and flash welds. Resistance welding depends on current, resistance, and time to generate heat for welding. Proper electrode pressure, material properties, and welding parameters ensure formation of a uniform weld nugget.

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    Definition of Resistance Welding

    Uploaded by

    Mitul patel
    204 views16 pages
    Resistance welding is a fusion welding process that uses heat generated by resistance of workpieces to electrical current flowing through them to join metals. It applies force before, during, and after current application to prevent arcing. Melting occurs at the faying surfaces. Common types include spot, seam, projection, upset, and flash welds. Resistance welding depends on current, resistance, and time to generate heat for welding. Proper electrode pressure, material properties, and welding parameters ensure formation of a uniform weld nugget.

    Original Description:

    b

    Original Title

    Spot Welding

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    Resistance welding is a fusion welding process that uses heat generated by resistance of workpieces to electrical current flowing through them to join metals. It applies force before, during, and after current application to prevent arcing. Melting occurs at the faying surfaces. Common types include spot, seam, projection, upset, and flash welds. Resistance welding depends on current, resistance, and time to generate heat for welding. Proper electrode pressure, material properties, and welding parameters ensure formation of a uniform weld nugget.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    204 views16 pages

    Definition of Resistance Welding

    Uploaded by

    Mitul patel
    Resistance welding is a fusion welding process that uses heat generated by resistance of workpieces to electrical current flowing through them to join metals. It applies force before, during, and after current application to prevent arcing. Melting occurs at the faying surfaces. Common types include spot, seam, projection, upset, and flash welds. Resistance welding depends on current, resistance, and time to generate heat for welding. Proper electrode pressure, material properties, and welding parameters ensure formation of a uniform weld nugget.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
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    of 16

    Definition of Resistance

    Welding
    • Resistance welding is a fusion welding process in
    which coalescence of metals is produced at the
    faying surfaces by the heat generated at the joint by
    the resistance of the work to the flow of electricity.
    • Force is applied before, during, and after the
    application of current to prevent arcing at the work
    piece.
    • Melting occurs at the faying surfaces during
    welding.
    Principal Types of Resistance Welds
    Electrodes Electrodes Electrodes Projection
    or Welding or Welding or Dies Welds
    Tips Wheels

    Spot Weld Seam Weld Projection Weld


    Electrodes or Dies

    Upset Weld Flash Weld

    After Welding After Welding


    [Reference: Resistance Welding Manual, RWMA, p.1-3]
    Typical Equipment of Resistance Spot Welding

    (a) (b)
    [Reference: Welding Process Slides, The Welding Institute]
    Advantages of Resistance Spot
    Welding
     Adaptability for Automation in High-Rate
    Production of Sheet Metal Assemblies

     High Speed

     Economical

     Dimensional Accuracy
    Limitations of Resistance Spot
    Welding
     Difficulty for maintenance or repair
     Adds weight and material cost to the product, compared with
    a butt joint
     Generally have higher cost than most arc welding equipment

     Produces unfavorable line power demands

     Low tensile and fatigue strength


     The full strength of the sheet cannot prevail across a spot
    welded joint
     Eccentric loading condition
    Resistance Welding
    • Resistance welding depends on three
    factors:
    – Time of current flow (T).
    – Resistance of the conductor (R)
    – Amperage (I).
    • Heat generation is expressed as
    Q = I2R T, Q = Heat generated.
    Heat = I2 RTK

    Where
    Is a function of:
    I = Current (Amps) Transformer Tap Setting
    R = Resistance (Ohms) Material Prop., & Pressure
    T = Time (Cycles 1/60 Control Setting
    Second)
    K = Heat Losses Conduction, Convection,
    Radiation
    Heat = I2 RTK

    Where
    Is a function of:
    I = Current (Amps) Transformer Tap Setting
    R = Resistance (Ohms) Material Prop., & Pressure
    T = Time (Cycles 1/60 Control Setting
    Second)
    K = Heat Losses Conduction, Convection,
    Radiation
    Factors Affecting Heat
    Generation (Q):
    • Welding pressure
    – as welding pressure increases both
    R and Q decrease.
    • Electrodes
    – deformation of electrodes
    increases contact area. As contact
    area increases, both R and Q
    decrease.
    Resistance Varies with Pressure

    Low Pressure Medium Pressure High Pressure

    (a) (b) (c)


    Upslope/Downslope, Hold Time,
    & Temper
    Electrode
    Pressure
    Current

    Weld Current
    Temper Current

    Upslope Downslope Temper


    Squeeze Time Weld Time Off Time Hold Time
    Heat Dissipation
    Water-Cooled Copper Alloy Electrode

    Base Metal
    Weld Nugget
    Base Metal

    Water-Cooled Copper Alloy Electrode


    Initial Resistance Through Weldment

    Top Electrode
    Water
    Weld
    Nugget

    Distance

    Resistance
    Bottom Electrode
    Temperature Readings of A Spot Welding Process
    (Note: Temp at Electrode Sheet Interface Higher than Bulk)

    Workpiece

    This illustration was taken


    about 4/60th of a second
    after the welding current
    starts.
    Temperature Distribution

    Temperature
    distribution at
    various
    location Electrode At the end of
    during welding time After 20%
    welding time
    welding.
    Workpiece

    Temperature
    Nugget Solidification

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