INTRODUCTION TO SPOT WELDING

Surface Resistance heating due to high current Fusion

Pressure
no consummable

Spot welding machines

Basic principle of spot welding

Heat is generated by the resistance & force is applied. Fusion takes place. Q = I2RT Water-cooled electrodes. Maximum job thickness 6 mm for uncoated steels and 4 mm for coated steels. workpieces with different thicknesses: The proportionate thickness of the components should not exceed 3:1. Indentation must be less than 20 % of workpiece thickness, preferably less than 10 %.
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Basic principle of resistance welding

Top Electrode
Cooling Water

Weld Nugget

Distance Resistance
Bottom Electrode
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Basic principle of resistance welding

Basic principle of resistance welding

Static Resistance Comparison

Electrode Plain-carbon Steel Stainless Steel

Workpieces

Higher Surface Resistance Chromium Oxide Electrode Resistance

Higher Resistances = Lower Currents Required

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Comparison of properties

Material

Resistivity m 1.6 x 10 8 (less than 1/10th of MS) 1.18 x 10 7 7.2 x 10 7 (6 times fore than MS)

Thermal conductivity W /m/K 401 (5 times more than MS) 80 15 (less than 1/6 th of MS)

Copper MS SS