DAY 2

WELDING TECHNOLOGY (CONTINUED)

RESISTANCE WELDING

It is a type of pressure welding used for joining pieces of sheet metal or wire. The
welding heat is obtained at the location of the desired weld by the electrical
resistance through the metal pieces to a relatively short duration, low voltage (from
6 to 10 volts only), high amperage (varying from 60 to 4000 amperes) electric
current. The amount of current can be regulated by changing the primary turns of
the transformer. When the area to be welded is sufficiently heated, the pressure
varying from 25 to 55 MPa is applied to the joining area by suitable electrodes until
the weld is solid.

Working Principle

Heat is generated by passing current through an electric resistance. Amount of heat

produced depends on

● Resistivity of the material

● Surface conditions
● Current Supplied
● Time

H= I2RT

Types of resistance welding

• Spot Welding • Seam Welding • Projection Welding

• Flash Butt Welding • percussion welding

Spot Welding

● Simplest type of resistance welding

● Two copper electrodes with anvil faces
● Create a circular nugget ( 4-7 mm )

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Seam Welding

● Also known as Continuous Spot Welding

● A roller type electrodes are used
● Creates a continuous weld joint
● The time and movement of electrode is controlled
● Weld overlap and work piece does not get too hot
● Used to create air tight joints

Projection Welding

● Heat is concentrated by means of projections made on surface

● Multiple welds at same time if multiple projections are made
● Efficient and not electrode dependent

Flash butt Welding

● Used to weld tubes and rods in steel industries
● Work pieces are clamped in the electrode holders
● high pulsed current in the range of 1,00,000 ampere
● Electrodes – One is Fixed and other is movable

Percussion welding

● To join dissimilar metals together that have small cross sectional areas
● A high temperature arc is formed from a short quick electrical discharge, followed
by application of pressure
● Advantages: shallow heat affected zone, very short cycle time

Applications
● Resistance welding - automotive industries
● Projection welding - production of nut and bolt
● Seam welding - produce leak proof joints required in small tanks, boilers etc.
● Flash welding -welding pipes and tubes

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Advantages

• It can weld thin (0.1 mm) as well as thick (20mm) metals.

• High welding speed.

• Easily automated.

• Both similar and dissimilar metals can be weld.

• The process is simple and fully automated so does not require high skilled labor.

• High production rate.

• It is an environmentally friendly process.

• It does not require any filler metal, flux and shielding gases.

Disadvantages

• High equipment cost.

• The thickness of the work piece is limited due to current requirements.

• It is less efficient for high conductive materials.

• High electric power required.

• Weld joints have low tensile and fatigue strength.

IMPORTANT POINTS

● Resistance welding is the welding process in which the metals to be joined are
heated to the plastic state by passing an electric current and then welding is
completed by the application of pressure
● In resistance welding heat is generated due to resistance between electrode
and work piece
● The electric resistance welding operates with high current and low voltage

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 ● In electric resistance welding, the voltage required for heating lies in the range
6-12 volt
● In electric resistance welding, both heat and pressure are used to induce
coalescence. The necessary pressure varies from 25-50 MN/m2
● The maximum heat at resistance welding is at interface between two plates
being joined
● Spot welding, projection welding and seam welding belong to the category of
electric resistance welding
● Seam welding is a continuous spot welding process
● In case of projection welding, diameter of projection is approximately equal
to thickness of the sheet
● Spot welding is used for welding both ferrous and nonferrous metal sheet
having thickness upto 10 mm
● The number of zones of heat generation in spot welding are five
● In a particular welding process metal to be joined is heated to the molten state
and allowed to solidify in the presence of a filler metal. Such a welding
process is known as fusion welding
● Gas welding, arc welding, brazing belongs to the fusion welding process
● Filler metal is used in gas welding
● In arc welding the maintenance voltage is of the order of 25-40 volt
● The current value in arc welding is decided by electrode size
● The arc in arc welding is created by contact resistance
● For producing sound weld in arc welding process, the optimum gap is 3mm
● In arc welding, arc length approximately equal to one and half time the
diameter of the electrode

Today’s exam will be based on the above topics. All the best.

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