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Fusion Welding - Resistance Welding (Cont.)

Resistance welding is a fusion welding process that uses heat generated by electrical resistance to join metal parts. The principal resistance welding process is resistance spot welding. The key steps in a resistance spot welding operation are: (1) inserting parts between electrodes, (2) squeezing the parts with pressure, (3) switching on current for 0.1-0.4 seconds to weld, (4) holding to allow solidification, and (5) opening the electrodes and removing the parts. Resistance welding has advantages of not requiring filler metal, enabling high production rates, and being automatable; disadvantages include high equipment costs and limited to lap joints.

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30 views

Fusion Welding - Resistance Welding (Cont.)

Resistance welding is a fusion welding process that uses heat generated by electrical resistance to join metal parts. The principal resistance welding process is resistance spot welding. The key steps in a resistance spot welding operation are: (1) inserting parts between electrodes, (2) squeezing the parts with pressure, (3) switching on current for 0.1-0.4 seconds to weld, (4) holding to allow solidification, and (5) opening the electrodes and removing the parts. Resistance welding has advantages of not requiring filler metal, enabling high production rates, and being automatable; disadvantages include high equipment costs and limited to lap joints.

Uploaded by

Smith
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Fusion Welding Resistance Welding

(Cont.)

Resistance Welding (RW)

A group of fusion welding processes that use a


combination of heat and pressure to accomplish
coalescence
Heat generated by electrical resistance to current flow at
junction to be welded
Principal RW process is resistance spot welding (RSW)

Describe the sequence of steps in the cycle of a resistance spot-welding operation.


Answer. The steps are (1) insert parts between electrodes, (2) squeeze parts
between the electrodes,
(3) weld, in which the current is switched on for a brief duration (0.1 to 0.4 sec), (4)
hold, during
which the weld nugget solidifies, and (5) open electrodes and remove parts.

Fusion Welding Resistance


Welding (Cont.)

Figure 31.12 Resistance


welding, showing the
components in spot
welding, the main
process in the RW
group.

Fusion Welding Resistance Welding


(Cont.)

Components in Resistance Spot Welding

Parts to be welded (usually sheet metal)


Two opposing electrodes
Means of applying pressure to squeeze parts between
electrodes
Power supply from which a controlled current can be
applied for a specified time duration

Fusion Welding Resistance Welding


(Cont.)
Advantages:
No filler metal required
High production rates possible
Lends itself to mechanization and automation
Lower operator skill level than for arc welding
Good repeatability and reliability
Disadvantages:
High initial equipment cost
Limited to lap joints for most RW processes
Skilled operators are required
Bigger job thickness cannot be welded

Fusion Welding Resistance


Welding (Cont.)

Applications of resistance welding

Joining sheets, bars and tubes.


Making tubes and metal furniture.
Welding aircraft and automobile parts.
Making cutting tools.
Making fuel tanks of cars, tractors etc.
Making wire fabrics, grids, grills, mesh
weld, containers etc.

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