Resistance Welding.1

Resistance Welding
Resistance Welding is “a group of welding processes wherein coalescence

is produced by the heat obtained from resistance of the work to electric
current in a circuit of which the work is a part, and by the application of
pressure and without use of filler metal”.
The amount of heat generated at the contacting area of the elements

to be welded, is obtained by Joule's law;
Where, I= Current, in Amperes
R= Resistance of the circuit at the contacting area of the elements, in ohms
t = time during which the current flows, in seconds
k = a constant to account for losses due to radiation and conduction ( k <1 )

Types of Resistance Welding:
• Resistance Spot Welding (RSW)
• Resistance Seam welding (RSEW)
• Resistance Projection Welding (RPW)
• Flash Butt Welding (FW)
• Upset Welding (UW)
• Percussion Butt Welding (PEW)

Resistance Spot Welding (RSW):
It is simplest type of resistance welding in which the work
pieces are held together under pressure. The copper electrodes
are brought in contact with work piece and current start to flow
through it. The work piece material applies some resistance in
flow of current which cause local heat generation.
The current start to flow though it which melt down the
interface surface. Now the current stopped to flow but the pressure
applied by electrode maintained for a fraction of second, while the
weld rapidly cooled. After it, the electrodes remove and brought to
contact at other spot. It will create a circular nugget. The nugget
size depends on size of electrode. It is generally about diameter 4-7
mm.
The diameter of the spot weld
d = 1.4 t + 4 mm, for t < 3 mm
d = 1.5 t + 5 mm, for t > 3 mm
Where t = thickness of the parts being
welded
Spacing of spot welds = 3 d
Distance between the nearest edge of the
plate and center of the weld
= 1.5 * electrode tip diameter
Resistance Seam welding (RSEW)
Seam welding is also called continuous spot welding in
which a roller type electrode is used to flow current through
work pieces.
First the rollers are brought in contact with work piece. A
high ampere current is passed through these rollers. This will
melt the interface surfaces and form a weld joint. Now the
rollers start rolling at work plates. This will create a continuous
weld joint.
Resistance Projection Welding (RPW)
Projection welding is same as spot welding except that the
current is concentrated at the spots to be welded, when a small
dimples or projections are embossed on one of the sheets.
Now the work pieces held between electrode and a large
amount of current pass through it. A small amount of pressure is
applied through electrode on welding plates. The current pass
through dimple which melt down it and the pressure causes the
dimple flatten and form a weld.
Flash Butt Welding (FW)
It is another type of resistance welding which is used to
weld tubes and rods in steel industries. In this process, two work
pieces which are to be welded will be clamped in the electrode
holders and a high pulsed current is supplied to the work piece
material.
In this two electrode holders are used in which one is fixed
and other is movable. Initially the current is supplied and
movable clamp is forced against the fixed clamp due to contact
of these two work pieces at high current, flash will be produced.
When the interface surface comes into plastic form, the current is
stopped and axial pressure is increased to make joint. In this
process weld is formed due to plastic deformation.
Upset Welding (UW)
In this process the ends of the two
parts to be joined together are clamped
in a position in the electrodes.
The movable head is moved
towards the fixed head until the
abutting surfaces of the work pieces are
in light contact.
Then the proper current is made to
flow across the interface for a preset
time, while the light pressure between
the two parts are maintained.
When the interface has been heated
to the welding temperature the current
is switch off and the welding pressure is
increased to form an upset.
Percussion Butt Welding (PEW)
It is one type of resistance butt-welding process. The parts to
be welded are clamped in copper jaws of the welding machine in
which one clamp is fixed and other one is movable. The movable
clamp is backed up against the pressure from a heavy spring.
The jaws act as electrodes. Heavy electric current is
connected to the work pieces. Now, the movable clamp is
released rapidly and it moves forward at high velocity. When the
two parts are approximately 1.6 mm apart, a sudden discharge of
electrical energy is released thereby causing an intense arc
between two surfaces.
Percussion Butt Welding (PEW)
The arc is extinguished by the percussion blow of the two
parts coming together with sufficient force to complete in 0.1
second. No upset or flash occurs at the weld. This method is
primarily employed to join dissimilar metals. This method is
limited to small areas of about 150 to 300 mm2.

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Resistance Welding

Resistance Welding is “a group of welding processes wherein coalescence

The amount of heat generated at the contacting area of the elements

Where, I= Current, in Amperes

R= Resistance of the circuit at the contacting area of the elements, in ohms

t = time during which the current flows, in seconds

k = a constant to account for losses due to radiation and conduction ( k <1 )

• Resistance Seam welding (RSEW)

• Resistance Projection Welding (RPW)

• Flash Butt Welding (FW)

• Upset Welding (UW)

• Percussion Butt Welding (PEW)

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