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Spot, Seam, Butt, Projection, Stud, Percussion Butt- Weldings

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• Resistance Welding is one of the oldest of the electric
welding processes in use by manufacturing industries today.
• The welding process is made by a combination of heat,
pressure, and time.
• We can easily join two materials.

How much current can flow is determined by a number of

factors:
Including the material thickness.
Material resistivity, Current level.
Cross-sectional area of the electrode tips and contact
surfaces.
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 Low voltage(0.5 – 10V)
But
Very high current (more
than1000A-100000A)
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• In resistance welding the coalescence is produced by the
heat obtained from resistance of the work to electric current in
a circuit of which the work is part.
• Here pressure is used and no filler metal is used.
• Heat generated can be calculated by joules law

Low voltage(0.5 – 10V)

But
Very high current (more than1000A-10000
• I – current in amperes.
• R – resistance of the circuit in ohms.
• t = time during which the current
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• Materials having higher thermal conductivity is difficult to
weld.
• So we have to give higher heat concentration on them.
• EX: aluminum, copper

• The strength
of the weld is depends on the
surface roughness, cleanliness of the
metal surface.
• Oil films, paint, oxide layers should be removed before
welding.

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• Overlapping metals are held between two bar type metal
electrode which apply pressure(2KN), while an electric
current is passed through them.
• Surface area of the metal in the centre is more highly
heated. So it becomes into plastic state.
• Then the current is switched off. Pressure is applied till
the weld spot(nugget) has solidified.

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In the middle the temperature is high shown in the graph(centre
horizontal line)
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• Spot diameter is depends on the electrode diameter. (3 to
6mm)
• Electrode must have
Good electrical, thermal conductivity.
• Electrodes are cold rolled copper with some Cd, Cr
alloys.
To prevent overheating electrodes are water cooled.
• 10000 A current for steels.
• 13000 A current for aluminium.

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• 8000- 10000 spots in a single car
• Cookware
• Railways- train building
• Spot welding is restricted to 3.2mm thick steel & 4mm
thick for aluminium.

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• Series spot welding
• Electrodes are like a disks.
• Work is continuously moving
• May be stich seam or overlapping seam

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• Electrode disks are cold rolled copper with some Cd, Cr
alloys.
• Electrodes are 40 to 350mm diameter.
• Current is 2000 to 5000A
• 5 to 6KN force
• 0.5 to 3.5 m/min speed.
• Water steam is directly used to cool the electrode.
• 0.25 to 3.2mm thickness can be joint.

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• Tanks, tubes and air tight joints.

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Electrodes are 40 to 350mm diameter.

5 to 6KN
force

Current is
2000 to
5000A
0.5 to 3.5 m/min speed

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• It is like a spot welding machine. But here a series of spot
welding is done at a time.
• Small dimples or projection are embossed or
coined on one of the sheets, when the current is
applied, the projections soften and are pushed back in
place by the electrode pressure as the weld spot(
nuggets ) form.
• The surface at the projection must be cleaned one.
• Used to join up to 3mm thin sheets.

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• Electric arc is produced between the flat surface
of workpiece and the stud.
• The arc melts the end of the stud and the stud is
forced on the work surface.
• A special welding gun is used. It contains spring,
solenoid, trigger, timer etc.
• To avoid oxide formation the front end of the stud is
coated with flux.
• This process is used for mass production.

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• Upset butt welding
• In butt welding the workpiece is clamped in copper
jaw(clamping device). And there may be some air gap is
between the workpiece. Here there is no arcing takes
place.
• Jaws are brought together in a solid contact when the
current flows through the point of contact of jaws to form
a locality of high electric resistance.
• At this point the applied pressure upsets or forges the
parts together.
• This process is mainly used for joining non-ferrous
materials such as rods, wire, tube etc.
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• Flash butt welding
• In butt welding the workpiece is clamped in copper
jaw(clamping device). Jaws are water cooled. Here heavy
current is passed.
• Workpiece are brought together in slight contact when the
current flows through the work pieces an electric arc or flash
is produced.
• Ends reach fusing temperature and power is switched off.
• Applying mechanical pressure the weld completed.
• The projection is removed by grinding.
• Used to join various cross section, to weld steel and
nonferrous alloy.
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• The resistance-welding processes already described usually
employ an electrical transformer to meet the power
requirements.
• Alternatively, the electrical energy for welding may be stored
in a capacitor.
• Percussion welding (PEW) utilizes this technique, in which the
power is discharged within 1 to 10 milliseconds to develop
localized high heat at the joint.
• The process is useful where heating of the components
adjacent to the joint is to be avoided, as in electronic
assemblies and electrical wires.

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How can you prepare
this component ?

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How can you joint
this?

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Can you identify the
joining process ?

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