Experiment no 2

To study and investigate the effect of varying current and voltage on the spot-welded
specimen.

1. Objective
To study about the spot-welding ad its principle and effect of changing the voltage and
current.

2. Apparatus

Fig. 1 Spot welding achene

3. Procedure

Theory
4. Spot welding
Spot welding can be defined as the process of welding in which we apply a large amount of
the heat at the point where the weld is to be required. This heat is provided by the
resistance to the electric current.
During the process the two separate workpieces are held together under the pressure
exerted by the electrodes. Two electrodes f copper are used to provide a large amount of
current at the spot which will provide enough amount of heat. This process will provide
enough heat that the weld will occur in just about 10 to 100 milliseconds.
If during the process, we will provide less heat the process will slow down, and we will get a
weld of low quality. There are chance that the workpieces are not joined well. If the heat
provided is high, then it will cause the metal to melt and it will not give the welding of a
good quality.

4.1. Principle
The gas tungsten-arc spot is made from one side only. The resistance spot weld is normally
made with electrodes on each side of the workpiece. Resistance spot welds may be made
with the workpiece in any position.
The resistance spot weld nugget is formed when the interface of the weld joint is heated
due to the resistance of the joint surfaces to electrical current flow. In all cases, of course,
the current must flow, or the weld cannot be made. The pressure of the electrode tips on
the workpiece holds the part in close and intimate contact during the making of the weld.
Remember, however, that resistance spot welding machines are NOT designed as force
clamps to pull the workpieces together for welding.

4.2. Safety symbols

i.

This symbol shows that there is a danger of the electric shock, so the user of the machine
should be aware and use appropriate precaution.

ii.
This symbol shows that this machine can cause damage to the eyes, so we must make
appropriate precautionary measures to avoid any damage or loss,

iii.
This symbol shows that there are danger rf flame. It can cause fire in case of negligence. Soo
we should show responsible behavior.

4.3. Heat generation

A modification of Ohm’s Law may be made when watts and heat are considered
synonymous. When current is passed through a conductor the electrical resistance of the
conductor to current flow will cause heat to be generated. The basic formula for heat
generation may be stated:
 H = I2R where H = Heat

I2 = Welding Current

Squared
R = Resistance
The secondary portion of a resistance spot welding circuit, including the parts to be welded,
is a series of resistances. The total additive value of this electrical resistance affects the
current output of the resistance spot welding machine and the heat generation of the
circuit.
The key fact is, although current value is the same in all parts of the electrical circuit, the
resistance values may vary considerably at different points in the circuit. The heat generated
is directly proportional to the resistance at any point in the circuit.

4.4. Time factor

As we know that the spot welding is basically done by the heat produced as a result of the
resistance provide to the flow of the current in the s=circuit. But there is another factor
through which we can control the heat produced in the spot welding which is the time
factor. We can produce heat buy applying a large amount of the current like in several
thousands ampere to be applied for a small fraction of time. So, in most cases it is usually
difficult to control the current factor because it is fixed in countries like its frequency is fixed
like in our country it is like 50Hz.

5. Ohm’s law
Ohms law provides us with the relation between the voltage and current.
It states that the current that is passing through the conductor is directly proportional to the
voltage by introducing a constant of proportionality that is resistance.
𝑉
𝐼=
𝑅
R shows the resistance which is the opposition to the flow of the current.
I am in amperes and V is in volts whereas R is in ohms.
According to the ohms law resistance is independent of the current. Due to this resistance
heat is produces in the fire or in any circuit path. This produced heat can be determined by
the formula:

𝐻 = 𝐼 2 𝑅𝑡
 6. Advantages
 Spot welding is quick and way easy
 We can perform spot welding without any filler material
 You do not need any special skills
 As we weld at a specific point so there is no open flame so there are less chances of
harm or skin damage

7. Disadvantages
 We can only weld overlapping plates
 Individual spots are not strong enough
 It does not provide good surface finish we have to perform several surface finish
steps to make it clear and clean
 It takes a lot of time and not convenient

8. Limitations
As in spot welding we must provide current to produce enough heat for the weld. If we are
unable to provide enough heat so we can not be able produce a good weld. Spot welding
does not give a good surface finish. Spot welding is not an economical process.

9. Applications in Pakistan
 Paper pencil making machine
 Crankshaft grinder machine
 Head surface machine
 Grass cutting machine

10. Steps of spot welding

There are three basic steps of spot welding which are as follow:

 First, we take the electrode of our required needs and bring it close to the material
or workpiece to be weld and apply the pressure with the help of the electrode. The
time for the weld depends upon the thickness of the plate.
 Then we apply current to the plate so that it will produce heat and the workpiece
will melt.
 After that we will allow the material to cool down so that the weld will be
completed.

11. Safety precautions

There is certain precautionary measure which we must take before using spot welding
which are as follows:
 Helmets with shields so that it can protect bus from UV radiations which will cause
certain chemical burns
 Goggles or glasses are necessary s that there should be no damage to the eyes
 We should wear closed shoes to prevent any contact of the fire or workpiece with
our foot
 Our clothes should be skin fit, clothes not should be too losing that they can be
captured by the machine