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Welding.Com » Introduction To Resistance Welding Introduction To Welding Slideshare

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Welding.Com  » Introduction to Resistance Welding

Resistance welding is one of the oldest of the electric welding processes in use by industry today. The weld is made by a combination of heat, pressure and time. As the name resistance welding implies, it is the resistance of the material to welded, to flow that causes a localized heating in the part.

The pressure exerted by the tongs and electrode tips, through which the flowing and the cross-sectional are of the welding tip contact surfaces.

Welding.Com  » Introduction to Resistance Welding introduction to welding slideshare

Fundamentals of Resistance Welding

Resistance flow causes localized heating in the joint and the weld is made.

The resistance spot weld nugget is formed internally with relation to the surface of the base metal. The below illustration shows a resistance spot weld nugget compared to a gas spot weld.

The gas spot is made from one side only. The resistance spot weld is normally made with the electrodes on each side of the workpiece. Resistance spot welds may be made with the workpiece in any position.

The resistence spot weld nugget is formed when the interface of the weld joint is heated due to the resistance of the joint surfaces to electric machines are NOT designed as force clamps to pull the workpieces together for welding.

Welding.Com  » Introduction to Resistance Welding introduction to welding slideshare

1 – Heat Generation

A modification of Ohm’s Law may be made when watts and heat are considered synonymous. When flow will cause heat to be generated. The basic formula for heat generation may be stated:

H = I R where:

H= HEAT, I2 = WELDING SQUARED, and R= RESISTANCE

The secondary portion of a resistance machine and the heat generation of the circuit.

The key fact is, although value is in the same in all parts of the electrical circuit, the resistance values may vary considerably at different points in the circuit.

Welding.Com  » Introduction to Resistance Welding introduction to welding slideshare

The resistance to the weldment in the most efficient manner. It is at the weldment that the greatest relative resistance is required. The term “relative” means with relation to the rest of the actual welding circuit.

There are six major points of resistance in the work area. They are:

  • The contact point between the electrode and top workpiece.
  • The top workpiece.
  • The interface of the top and bottom workpieces.
  • The bottom workpiec.e
  • The contact between the bottom workpiece and the electrode.
  • Resistance of electrode tips.

2 – Time

Resistance is flowing.

3 – Pressure

Welding.Com  » Introduction to Resistance Welding introduction to welding slideshare

The effect of pressure on the resistance spot weld should be carefully considered. The primary purpose of pressure is to hold the parts to be welded in intimate contact at the joint interface. This action assures consistent electrical resistance and conductivity at the point of the weld. The tong and electrode tips should NOT be used to pull the workpiece together. The resistance machine is not designed as an electrical “C” clamp. The parts to be welded should be intimate BEFORE pressure is applied.

4 – Electrode Tips

Copper is the base material normally use for resistance to the workpiece, to be the focal point of the pressure applied to the weld joint, to conduct heat from the work surface and to maintain their integrity of shape and characteristics of thermal and electrical conductivity under working conditions.

Information courtesy of Miller Electric

Welding.Com  » Introduction to Resistance Welding

Welding.Com  » Introduction to Resistance Welding introduction to welding slideshare

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