Spot Welding

Classification of welding processes:

ARC WELDING
• Carbon arc THERMIT WELDING
• Metal arc SOLID STATE WELDING
• Metal inert gas • Friction
• Tungsten inert gas • Ultrasonic
• Plasma arc • Diffusion
• Submerged arc • Explosive
• Electro-slag NEWER WELDING
GAS WELDING • Electron-beam
• Oxy-acetylene • Laser
• Air-acetylene RELATED PROCESS
• Oxy-hydrogen • Oxy-acetylene cutting
• Arc cutting
RESISTANCE WELDING
• Hard facing
• Butt • Brazing
• Spot • Soldering
• Seam
• Projection
• Percussion
 Definition of Resistance
Welding
• Resistance welding is a fusion welding process in
which joining of metals is produced at the faying
surfaces by the heat generated at the joint due to the
resistance of the work to the flow of electricity.
• Force is applied before, during, and after the
application of current to prevent arcing at the work
piece.
• Melting occurs at the faying surfaces during welding.
Principal Types of Resistance Welds
Electrodes Electrodes Electrodes Projection
or Welding or Welding or Dies Welds
Tips Wheels

Spot Weld Seam Weld Projection Weld

Electrodes or Dies

Upset Weld Flash Weld

After Welding After Welding

[Reference: Resistance Welding Manual, RWMA, p.1-3]
Typical Equipment of Resistance Spot Welding

Electrode

Electrode

Diameter of the weld spot is in the range (3 - 12 mm).

 Electrodes

Truncated cone Dome Pointed

• Electrode tips wear during service, causing nugget

size to decrease
 Resistance Welding
• The principle of resistance welding is the Joule
Heating Law
• Joule heating, also known as ohmic heating and
resistive heating, is the process by which the passage
of an electric current through a conductor releases
heat.
• The amount of heat released is proportional to the
square of the current such that:

Q = I2Rt
Spot Welding Principle
Advantages of Resistance Spot
Welding
 Adaptability for Automation in High-Rate
Production of Sheet Metal Assemblies

 High Speed

 Economical

 Dimensional Accuracy
 Limitations of Resistance Spot
Welding
 Difficulty for maintenance or repair

 Generally have higher cost than most arc welding equipment

 Produces unfavorable line power demands

 Low tensile and fatigue strength

 Eccentric loading condition

 Applications of Resistance
Welding
Resistance Welding (RW) is used for joining:

• vehicle body parts

• fuel tanks

• domestic radiators

• pipes of gas oil and water pipelines

• turbine blades

• railway tracks
Typical car body has about 10,000 spot welds
Thanks…!!!