Resistance Welding

A
SEMINAR
ON
“RESITANCE WELDING”
SUBMITTED TO- PRESENTED BY-

S. CHATTOPADHAYA YOGENDRA INGH
(ASSOCIATE PROFESSOR) (2012MT0158)
Resistance Welding
• The resistance of metal to
the localized flow of
current produces heat.
• Process variables
– Current
– Time
– Force
Spot welding
DEFINITION
• Developed in the early 1900’s
• A process in which the heat required for welding is

produced by means of electrical resistance across the two
components
• RW does not requiring the following:

– Consumable electrodes
– Shield gases
– Flux
MATHEMATICAL FORMULATION
The heat generated in resistance welding is

given by the general expression
H=I2RT
Where
H=heat generated
I=current in amperes
R=resistance in ohms
T=flow time of currents in seconds
MODIFICATION IN FORMULA
H=I2RTK
Where
K<1
TYPES OR RESISTANCE WELDING
 RESISTANCE SPOT WELDING

 RESISTANCE SEAM WELDING
 RESISTANCE PROJECTION WELDING
 RESISTANCE FLASH WELDING
 STUD ARC WELDING
Electrodes
Truncated cone Dome Pointed
• Electrode tips wear during service, causing

nugget size to decrease.
• Zinc-coating on steel alloys with copper
electrodes to form brass.
• Copper base materials.
Electrodes may be
single or multiple.
electrode
electrode
RESISTANCE SPOT WELDING
• The strength of welds depends on surface roughness cleanliness
• Accurate control of and timing of electric current and of pressure
are essential in resistance welding
Nugget
diameter is up
to 10 mm.
Fig: a Cross-section of a spot

weld,showing the weld nugget and
the indentation of the electrode on
the sheet surfaces.This is one of the
most commonly used process in
sheet-metal fabrication and in
automotive-body assembly
RESISTANCE SPOT WELDING
• RSW uses the tips of two opposing solid cylindrical electrodes
• Pressure is applied to the lap joint until the current is turned

off in order to obtain a strong weld
Fig: Sequence in the resistance spot welding

RESISTANCE SEAM WELDING
• RSEM is modification of spot welding wherein the electrodes are
replaced by rotating wheels or rollers
• The electrically conducting rollers produce a spot weld
• RSEM can produce a continuous seam & joint that is liquid and gas
tight
Fig : (a) Seam-Welding Process in which rotating rolls act as electrode (b)
Overlapping spots in a seam weld. (c) Roll spot weld (d) Resistance-welded gasoline
tank
Roll spot weld Overlapping seam weld Continuous seam weld
Resistance Seam Welding
Welding speed is 1.5 m/min

for thin sheet.
APPLICATION-
RESW is used in-
Longitudinal seam of cans for
household products ,mufflers,
gasoline tanks & other
containers.
RESISTANCE PROJECTION
WELDING
• The electrodes exert
pressure to compress the
projections.
• Nuts and bolts can be welded to sheet and

plate by this process.
• Metal baskets, oven grills, and shopping carts

can be made by RPW.
• Different thickness plate can be welded.
RESISTANCE PROJECTION
WELDING
• RPW is developed by
introducing high
electrical resistance
at a joint by
embossing one or
more projections on
the surface to be
welded
• Weld nuggets are

similar to spot
welding
Fig: a) Resistance projection Welding b)A welded

bracket c) & d) Projection welding of nuts r
threaded hosses and stack
FLASH WELDING
• It is also known as arc welding.
• Heat is generated from the arc as the ends as the two members
contacts
• An axial force is applied at a controlled rate
• Weld is formed in plastic deformation
Fig : Flash-welding process for end-to –end welding of solid rods or tubular parts
APPLICATION OF FLASH WELDING
• Suitable for end to end(1-75 mm dia) or edge to

edge(.2-2.5 mm thick) joining of similar or
dissimilar metals.
• Joining pipe and tubular section shapes for
metal furniture & window.
• welding high-speed steels to steel shanks.
• welding the ends of coils of sheet or wire for
continuous operations of rolling mills &wire-
drawing equipment.
Stud Welding
• Small part or a threaded rod or hanger serves as a electrode
• Also called as Stud arc welding
• Prevent oxidation to concentrate the heat generation
• Portable stud-welding is also available
Fig:The sequence of operation in stud welding,which is used for welding bars

threaded rods and various fasteners onto metal plates
APPLICATION OF STUD ARC
WELDING
Numerous application in the automotive
,construction ,appliance and shipbuilding
industries.
Advantages of Resistance Welding
• Similar and dissimilar metals can be jointed.
•High speed, < 0.1 seconds in automotive spot

welds.
• Excellent for sheet metal applications, < ¼-inch.
• Generally No filler metal.
• No consumable electrodes, shielded gases or

flux.
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
• process is suitable for
manufacturing plants &
machine shops
THANKING YOU

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A

SUBMITTED TO- PRESENTED BY-

• A process in which the heat required for welding is

• RW does not requiring the following:

The heat generated in resistance welding is

 RESISTANCE SPOT WELDING

Truncated cone Dome Pointed

• Electrode tips wear during service, causing

Fig: a Cross-section of a spot

• Pressure is applied to the lap joint until the current is turned

Fig: Sequence in the resistance spot welding

Welding speed is 1.5 m/min

• Nuts and bolts can be welded to sheet and

• Metal baskets, oven grills, and shopping carts

• Weld nuggets are

Fig: a) Resistance projection Welding b)A welded

• Suitable for end to end(1-75 mm dia) or edge to

Fig:The sequence of operation in stud welding,which is used for welding bars

• Similar and dissimilar metals can be jointed.

•High speed, < 0.1 seconds in automotive spot

• Excellent for sheet metal applications, < ¼-inch.

• Generally No filler metal.

• No consumable electrodes, shielded gases or

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