3-2 Spot Welding

Spot Welding
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 or Welding Tips Electrodes or Welding Wheels Electrodes or Dies
Projection Welds
Spot Weld
Seam Weld
Electrodes or Dies
Projection Weld
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 I = Current (Amps) R = Resistance (Ohms) T = Time (Cycles 1/60 Second) K = Heat Losses Is a function of: Transformer Tap Setting Material Prop., & Pressure Control Setting Conduction, Convection, Radiation
Heating Value of Current = RMS Current Irms=0.707 Ipeak
Block Diagram of Single-Phase Spot Welder

Contactor
Main Power Line
Spot Weld
N=np/ns Vs= Vp/N Is = Ip N
Heat = I2 RTK Where I = Current (Amps) R = Resistance (Ohms) T = Time (Cycles 1/60 Second) K = Heat Losses Is a function of: Transformer Tap Setting Material Prop., & Pressure Control Setting Conduction, Convection, Radiation
Contact-Resistance Measurement
Electrode Rec Force
Small Current Rec Rsc Rv Rv
Rec = contact resistance between electrode and sheet surface

Rsc = contact resistance at the faying surface Rv = volume resistance of the sheets
Rtotal
Rec
Contact Area
Rec Electrode Force
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.
(a) Pickled Conditions
Surface Condition
Steel
(b) Rusted Conditions Oils/Dirt Oxide
Resistivity
Steel
Steel
Rusty
Polished Pickled
Oxide Oils/Dirt Steel
Electrode Force
Resistance Varies with Pressure
Low Pressure
Medium Pressure
High Pressure
(a)
(b)
(c)
Volume-Resistance Measurement
Electrode Force
Small Current Rec Rsc Rtotal Rec Rv Rv
Rec = contact resistance between electrode and sheet surface

Rsc = contact resistance at the faying surface Rv = volume resistance of the sheets
Contact Area
Rv Electrode Force
Resistivity as a Function of Temperature

130 120 110 100 90 80 70 60 50 40 30 20 10
Resistivity, mW-cm
HSLA
Low Carbon
100 200 300 400 500 600 700 800
Temperature, C
[Reference: Welding in the Automotive Industry, D.W. Dickinson, p.125]
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 during welding.

Workpiece
Electrode
At the end of welding time
After 20% welding time
Temperature

3-2 Spot Welding

Uploaded by

Copyright:

Available Formats

3-2 Spot Welding

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

3-2 Spot Welding

Uploaded by

Copyright:

Available Formats

Spot Welding

Definition of Resistance Welding

Principal Types of Resistance Welds

[Reference: Resistance Welding Manual, RWMA, p.1-3]

Typical Equipment of Resistance Spot Welding

[Reference: Welding Process Slides, The Welding Institute]

Advantages of Resistance Spot Welding

Adaptability for Automation in High-Rate

High Speed Economical Dimensional Accuracy

Limitations of Resistance Spot Welding

Eccentric loading condition

Heat generation is expressed as Q = I2R T, Q = Heat generated.

Heating Value of Current = RMS Current Irms=0.707 Ipeak

Block Diagram of Single-Phase Spot Welder

Main Power Line

N=np/ns Vs= Vp/N Is = Ip N

Small Current Rec Rsc Rv Rv

Rec = contact resistance between electrode and sheet surface

Factors Affecting Heat Generation (Q):

(a) Pickled Conditions

(b) Rusted Conditions Oils/Dirt Oxide

Oxide Oils/Dirt Steel

Resistance Varies with Pressure

Small Current Rec Rsc Rtotal Rec Rv Rv

Rec = contact resistance between electrode and sheet surface

Resistivity as a Function of Temperature

100 200 300 400 500 600 700 800

Base Metal Weld Nugget Base Metal

Water-Cooled Copper Alloy Electrode

Initial Resistance Through Weldment

Resistance Bottom Electrode

Temperature Readings of A Spot Welding Process

Temperature distribution at various location during welding.

At the end of welding time

After 20% welding time

You might also like