Resistance Welding

RESISTANCE WELDING
• Definition: Resistance welding is a group of welding

processes in which welding heat is obtained by resistance
of the work to the flow of electric current and by the
application of pressure. No filler metal or flux is added.
• Principle: In resistance welding, a low voltage and very
high current(typically 5000 A) is passed through the joint
for a very short time(typically .25 sec). This high
amperage heats the joint because heat generated in
resistance welding can be expressed as: H= I2RT where
H= total heat, I= Electric current, T= time for which
electric current is passing and R= resistance of the joint.
• Electrodes: Copper cadmium is used for welding of Al
and Mg. Copper chromium is used for welding of mild
steel and low alloy steel
• Advantages:
1. Very little skill is required to operate the resistance welding machine.
2. High production rate so well suited for mass production.
3. Heating of workpiece is confined to a very small part, which results in less distortion.
4. No filler rod and flux needed.
5. It is possible to weld dissimilar metals as well as metal plates of different thickness.
6. Semi- automatic equipments are available.
7. It is very economical process.
• Disadvantages:
1. The initial cost of equipment is high.
2. Certain resistance welding operations are limited only to lap joints.
3. Skilled persons are needed for maintenance.
4. Bigger job thickness cannot be welded.
• Applications:
1. Joining sheets, bars and tubes.
2. Making metal furniture.
3. Making fuel tanks of cars, tractor etc.
4. Making containers.
5. Welding aircraft and automobile parts.
Spot Welding
• Spot welding is a resistance welding process in which overlapping sheets are joined by local
fusion at one or more spots by the heat and pressure which is applied by the electrodes
one above and other below the workpiece.
• Procedure:
1. The job should be clean. It should be free from grease, dirt, paint, scale, oxides etc.
2. Clean the electrode tip surface. Very fine emery cloth may be used for routine cleaning.
3. Water is kept running through the electrodes in order to cool the weld and avoid the
electrode from getting overheated.
4. Proper welding current has been set on the current selector switch.
5. Proper time has been set on weld timer.
6. Electrode are brought together against the overlapping workpieces and pressure is
applied so that the surfaces of the two workpieces come in physical contact with each
other.
7. Welding current is switched on for a definite period of time.
8. As the current passes a small area where the workpieces are in contact is heated and
spot weld takes place. The temperature of the weld zone is approx. 815°C to 930 °C.
9. After the welding takes place, the welding current cut off. Extra electrode force is then
Spot Welding
• Advantages:
1. Low Cost.
2. Less skilled worker can perform this welding.
3. Higher productivity.
4. Operation can be made automatic or
semiautomatic.
5. No edge preparation is needed.
• Applications:
1. Welding of low carbon steels, high speed steels,
stainless steels, Al, Cu, Ni, Ni alloys etc.
2. In automobile and aircraft industries.
3. Steel household furniture.
4. Containers.
Seam Welding
• Seam welding is a resistance welding process in which overlapping
sheets are joined by local fusion progressively along a joint by rotating
the circular electrodes.
• Principle:
1. Workpieces to be seam welded are cleaned, overlapped suitably and
placed between the two circular electrodes which clamps the
workpiece together by the electrode force.
2. Switch on the coolant supply.
3. Switch on the current supply. As the first current impulse is applied,
the power driven circular electrodes are set in rotation and the
workpieces steadily move forward.
4. If the current is put off and on quickly, a continuous fusion zone made
up of overlapping nuggets is obtained. It is known as stitch welding.
5. If individual spot welds are obtained by constant and regularly timed
interruption of the welding current, the process is known as roll(spot)
welding.
• Advantages:
1. It can produce gas tight or liquid tight joints.
2. Overlap can be less than spot or projections welds.
3. Several parallel seams may be produced.
• Disadvantages:
1. Cost of equipment is high as compared to spot welding set.
2. Welding can be done only along a straight or uniformly
curved line.
3. It is difficult to weld thickness greater than 3 mm.
• Applications:
1. It is used for welding of stainless steel, aluminium and
its alloys, nickel and its alloys, magnesium allooys etc.
Flash Butt Welding
• In his welding, the two pieces to be joined are held tightly together
and the heat is obtained by means of an arc.
• Procedure:
1. In this welding, one workpiece to be joined is clamped in moving
platen while other is mounted on fixed platen.
2. The workpiece held in the movable platen is moved to bring
towards the workpiece which held in stationary platen.
3. When the welding current is switched on, flashing is established.
4. This flashing produces the welding heat. When sufficient heat is
produced, more pressure is applied so that sound joint takes place.
5. After that, welding current is cut off and workpieces are
unclamped.
• Advantages:
1. It consumes less welding current than upset butt weld process.
2. Flash welding offers strength factor upto 100%.
3. Preparation of weld surface is not required.
4. The process is cheap.
5. It is faster process.
• Disadvantages:
1. Concentricity and straightness of workpiece during welding is difficult to
maintain.
2. The shapes of the workpieces should be similar which is not always possible.
3. Chances of fire hazards are there.
4. Flashes may cause eye trouble.
• Applications:
1. It is used for the welding of bars, rods and tubes.
2. It is also used for the welding of saw blades into continuous loops, taps and
reamers to alloy steel shanks.
Percussion Welding
• In this resistance welding, welding heat is
obtained by a rapid discharge of stored
electrical energy. Pressure is applied
percussively during and immediately following
the electric discharge. The electrostatic
capacitors are used to store the electrical
energy.
• Advantages:
1. Arc temperature is more as compared to flash butt welding.
2. Strong joints are produced.
3. In this welding, there is no or very less upsetting.
• Disadvantages:
1. Limited to butt joints only.
2. Equipment is expensive.
• Applications:
1. It is used for welding stellite tips
to tools, silver contact tips to
copper, copper to aluminium etc.
2. It is used in telephone industry.
3. It is also used for welding fine
wire leads to filaments in lamps

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RESISTANCE WELDING

• Definition: Resistance welding is a group of welding

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