Resistance Welding: Resistance Welding Is A Pressure Welding Technique Using High

Resistance Welding
Resistance Welding is a pressure welding technique using high

current and low voltage
The current passing through the two overlapping workpieces causes

local heating and tempeature of the metallic pieces raises to the
fusion point due to resistance offered by the workpieces to flow of
current
Subseqent aplplication of pressure results in permanent joinining of

the workpieces by the formation of weld without the use of filler
material
Workpieces are placed between two rods or wheels(rolls), which

serve as conductor for producing welds
AC electric current is supplied through copper electrodes or rolls

connected to the secondary coil of a welding transformer.
It is used for welding thin sheets of similar metallic materials

Voltage : 1 to 25 V
At 15000 Amp
H = Amount of heat generated at the contacting area of the elements to be welded ( Joules)
I = current ( Amperes )
R = resistance of the ckt at contacting area ( ohms)
T = time for which electric current passes through the joint. ( sec ) ( 0 . 25 sec )
The following metals may be welded by Resistance Welding:
•Low carbon steels - the widest application of Resistance Welding
•Aluminum alloys
•Medium carbon steels, high carbon steels and Alloy steels (may be
welded, but the weld is brittle)
Advantages of Resistance Welding:

•High welding rates;
•Low fumes;
•Cost effectiveness;
•Easy automation;
•No filler materials are required;
•Low distortions.
Disadvantages of Resistance Welding:
•High equipment cost;
•Low strength in case of discontinuous welds;
•Thickness of welded sheets is limited - up to 1/4” (6 mm);
Applications :
Resistance Welding (RW) is used for joining vehicle body

parts, fuel tanks, domestic radiators, pipes of gas oil and
water pipelines, wire ends, turbine blades, railway
tracks.
Types of Resistance Welding are:
•Resistance spot welding

•Resistance seam welding
Resistance butt welding 1. Upset welding
2. Flash welding
•Resistance projection welding

Diameter of the
weld spot is in the
range (3 - 12 mm).
Figure : Resistance welding, showing the components

in spot welding, the main process in the RW group.
Resistance Spot Welding (RSW)
Spot Welding is a Resistance Welding (RW) process, in which two or
more overlapped metal sheets are joined by spot welds.
The method uses pointed copper electrodes providing passage of

electric current. The electrodes also transmit pressure required for
formation of strong weld.
Diameter of the weld spot is in the range 1/8” - 1/2” (3 - 12 mm).
It consist of a transformer core having primary and secondary

Winding. One end of secondary winding is connected to upper
Electrode and other electrode is connected to lower electrode.
The workpieces to be weld are pressed between tips of the electrodes

and high current at low voltages is passed through the workpieces.
Due to resistance offered by the workpieces ( sheet metal ) to

the flow of current , the temperature at the contact surfaces rises to
fusion point and the weld is completed on freezing. The operation is
repeated by changing the position of the workpiece plate to get the
weld at another point.
Spot welding is widely used in automotive industry for joining vehicle

body parts and in metal furniture.
Resistance Welding Cycle
Spot welding equipment
1.Fixed type:
(a)Rocker arm type
(b) press type
2.Portable type:
(a)Pincer type
(b) C-clamp type
Spot welding electrode
Heat balance
Typical car body has about 10,000 spot welds
Seam Welding (RSW)
Seam Welding is a Resistance Welding process of

continuous joining of overlapping sheets by passing
them between two rotating electrode wheels. Heat
generated by the electric current flowing through
the contact area and pressure provided by the
wheels are sufficient to produce a leak-tight weld.
Seam Welding is high speed and clean process,

which is used when continuous tight weld is required
(fuel tanks, drums, domestic radiators,gasoline
tanks, automobile muffler ).
Figure : Resistance seam welding (RSEW).
Side view
Resistance Seam Welding

Spot welding Seam welding
1. The electrodes are a 1. Electrodes are a pair of
pair of copper rods rotating copper rolls between
between which the which sheets to be welded
sheets to be welded are passed
are positioned
2. The welding takes 2. The seam weld joints are
place at discrete continuous
intervals
3. It is used for 3. It is used to weld
components such as components such as a fuel
flat sheets , panels tank shells & other
as in car bodies. application which require the
joint to be leak proof
Resistance Projection Welding
Figure : Resistance projection welding (RPW): (1) start of operation, contact

between parts is at projections; (2) when current is applied, weld nuggets
similar to spot welding are formed at the projections.
A resistance welding process in which coalescence occurs at one or more

small contact points on parts
Contact points determined by design of parts to be joined .May consist of
projections, embossments, or localized intersections of parts
•Resistance Butt Welding
It is of three types
1. Upset welding
2. Flash welding
3. Percussion welding
Upset Butt Welding
Resistance Butt Welding (UW)
Upset Welding is used to join the pieces end to end

The process is best suited to rods , pipes and many other parts
Of uniform cross section.
In upset butt welding , the parts are clamped and brought in solid
contact and current is applied so that the heat is generated through
the contact areas of the parts.
When the temperature of the interface reaches to plastic state, the

current is switched off and the two parts are pressed together firmly.
This results in lateral flow of the surfaces oxide layers. This action of
pressing together is called upsetting.
Butt welding is used for welding small parts. The process is highly
productive and clean.
Flash Butt Welding
Flash Welding (FW)
Flash welding is similar to upset welding except that the heat is

obtained by means of an arc than the simple resistance heating.
The two parts are brought together and the power supply is switched
on.
As the parts are moved closer , flashing or arcing raises the
temperature
of the parts to a welding temperature.
Now power is switched off and two parts are rapidly pressed (forced)
together causing a small upset. This squeezes out liquid metal and
oxides ,
formed on the joint surfaces and the two parts are welded together.
Thick pipes, ends of band saws, frames, aircraft landing gears are
produced
by Flash Welding.
Percussion welding

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Resistance Welding

Resistance Welding is a pressure welding technique using high

The current passing through the two overlapping workpieces causes

Subseqent aplplication of pressure results in permanent joinining of

Workpieces are placed between two rods or wheels(rolls), which

AC electric current is supplied through copper electrodes or rolls

It is used for welding thin sheets of similar metallic materials

Advantages of Resistance Welding:

Resistance Welding (RW) is used for joining vehicle body

Types of Resistance Welding are:

•Resistance spot welding

•Resistance projection welding

Figure : Resistance welding, showing the components

The method uses pointed copper electrodes providing passage of

It consist of a transformer core having primary and secondary

The workpieces to be weld are pressed between tips of the electrodes

Due to resistance offered by the workpieces ( sheet metal ) to

Spot welding is widely used in automotive industry for joining vehicle

Seam Welding is a Resistance Welding process of

Seam Welding is high speed and clean process,

Resistance Seam Welding

Figure : Resistance projection welding (RPW): (1) start of operation, contact

A resistance welding process in which coalescence occurs at one or more

Upset Welding is used to join the pieces end to end

When the temperature of the interface reaches to plastic state, the

Flash welding is similar to upset welding except that the heat is

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