8.

Resistance Spot Welding,

Resistance Projection Welding

and Resistance Seam Welding
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 105

Figure 8.1 shows an extract from the classification of the welding methods according to DIN
1910 with a detailed account of the conductive resistance pressure welding.

In the case of resistance pressure welding, the heating occurs at the welding point as a con-
sequence of Joule resistance heating caused by current flow through an electrical conductor,
Figure 8.2. In spot and pro-
welding jection welding, the plates
to be welded in overlap.
pressure fusion
welding welding Current supply is carried
out through spherical or
cold pressure resistance pressure friction welding
welding welding
flat electrodes, respec-
induction pressure Conduction pressure tively. In roller seam weld-
welding welding
ing, two driven roller elec-
resistance spot projection roller seam resistance butt flash butt
welding welding welding welding welding trodes are applied. The

br-er8-01e.cdr © ISF 2002

plates to be welded are
Classification of Welding mainly overlapped. The
According to DIN 1910
heat input rate Qinput is
Figure 8.1 generated by resistance
heating in a current-
carrying conductor, Figure
spot welding roller seam welding projection welding

workpieces overlap
workpiece usually in general
workpieces with elevations

8.3. However, only the ef-

electrode overlap (concentration of electicity)

weld nugget
driven roller electrode

spot rows (stitch weld,

workpieces overlap

pad electrode
fective heat quantity Qeff is
roller spots)
several joints in a single weld

weld nugget joint instrumental in the forma-
1 tion of the weld nugget.
1 3
2
2
3
2 1 3
Qeff is composed of the

4
input heat minus the dissi-
5
1
1
pation heat. The heat loss
1
arises from the heat dissi-
1 electrode force
2 elektrodes 4 loaded area 5 projection
3 production part pation into the electrodes
br-er8-02e.cdr

and the plates and also

from thermal radiation.
Figure 8.2

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 106

The resistance during resistance heating is composed of the contact resistances on the two
plates and of their material resistance. The reduction of the electrode force down to 90% in-
creases the heat input rate by 105%, the reduction of the welding current down to 90% de-
creases the heat rate to 80% and a welding time reduction to 90% decreases the heat rate to
92%.

The time progression of the resistance is shown in Figure 8.4. The contact resistance is
composed of the interface resistances between the electrode and the plate (electrode/plate)
and between the plates
(plate/plate). The resis- Fel: electrode force
Qeff: effective heat
tance height is greatly de- Qinput: total heat input Fel
I: current (time dependence)
pendent on the applied Q1:
Q2 :
heat losses
losses into the electrodes
Q4 Q2 Q4
Q3 : losses into the sheet metal
electrode force. The higher Q4: losses by heat radiation
R(t): total resistance Q3
this force is set, the larger Rmaterial(t):
Rc(t):
material resistance Qeff
Q3
contact resistance

are the conductive cross- Qeff = Qinput - Q1l

Q4 Q4
t=tS Q2
sections at the contact Qinput = C 2
I (t) R(t) dt
t=0
Fel
points and smaller the re- Q1 = Q2 + Q3 + Q4

sistances. The contact sur- R(t) = Rmaterial(t) + Rc(t)

br-er8-03e.cdr © ISF 2002

faces, which are rapidly

increasing at the start of
welding, effect a rapid re-
duction of interface resis-
tances.
Heat Balance in Spot Welding
Figure 8.3
theoretical contact area
100% metallic conduction contact
mOhm
proportion at room temperature

With the formation of the total resistance

low electrode force
high resistance
resistance

weld nugget the interface sum of material resistance

high electrode force

resistances between the low resistance

plates disappear. During sum of contact resistances

proportion after first
milliseconds welding time

the progress of the weld 5 10 periods

surface resistance is
welding time collapsed,
the material resistance in- a3 is highly extended
A1: area out-of-contact
A2: contact area with high resistance
creases from a low value A3: contact area completely conductive
br-er8-04e.cdr

(surrounding temperatures)
to a maximum value above
the melting temperature. Figure 8.4

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 107

Figure 8.5 shows dia-

electrode force resistance rate
grammatically the different
resistances during the spot R1
R3

welding process with act- R3

R6
_
~ R6
ing electrode force, but R5
R7

without welding current. R4

R7

Weld nugget formation R5 R2

R4

must therefore start in the 0 100 200

R [µOhm]
joining zone because of
the existing high contact
br-er8-05e.cdr

resistance there.

Figure 8.6 shows directly Figure 8.5

cooled electrodes for resis-
tance welding. The coolant cooling tube
cooling drill-hole
is normally water. In the
6-8

cooling tube, the cooling slope

10 - 20
2-5

water is transported to the

electrode base. The dia-
gram shows the tempera-
ture distribution in the elec-
°C
trodes and in the plates.
The maximum temperature
br-er8-06e.cdr © ISF 2002

is reached in the centre of

Electrode Cooling
the weld nugget and de-
creases strongly in the Figure 8.6
electrode direction.

Sequence of a resistance spot welding process, Figure 8.7:

1->2 Lowering of the top electrode
2->3 Application of the adjusted electrode force Set-up time tpre, sequence
3->4 Switching-on of the adjusted welding current for the period of the welding time tw. For-
mation of the weld nugget in the joining zone of both workpieces.

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 108

An example shows the macrosection of a weld nugget after the welding time has
ended.
4->5 Maintaining the electrode force for the period of the set post-weld holding time th.
5->6 Switching-off the force generating system and lifting the electrodes off the workpiece.

The functions of the set-up time and the post-weld holding time are listed in Figure 8.8. De-
pendent on the welding task different force and current programs can be set in the weld-
ing machines, Figure 8.9. In the top the simplest possible welding program sequence is
shown: The application of the electrode force, the set-up time sequence tpre, the switching-on
of the welding current and the sequence of the welding time tw, the sequence of the post-
weld holding time th and the switching-off of the force generating system. The diagram in the
centre is almost identical to the one just described.
Merely in the welding current range, welding is carried out using an adjustable current rise (7)
and current decay (8). The diagram below depicts a more sophisticated current program. In
addition, welding is carried out with a variable electrode force (2) and with preheating (4) and
post-heating current (6). Dependent on the control system, the process can be influenced by
adjustment.

Fel Iw
electrode force Fel set-up time

- compressing the workpiece

welding current Iw - build-up of electrode force to preset
value
- setting-up of reproducible resistance
time t before welding
- electrode resting after bounce
- preventing resting of electrode on
tpre tw th workpiece under electricle voltage

top electrode
postweld-holding time

- holding time of workpiece during

cooling of molten metal
workpiece
- prevention of pore formation in the
lower electrode weld nugget welding nugget
- prevention of lifting the electrode
under voltage

The postweld-holding time has

influence on the weld point hardening
within certain limits.
insufficiently melted weld nugget totally melted weld nugget

br-er8-07e.cdr © ISF 2002 br-er8-08e.cdr © ISF 2002

Time Sequence of Functions of Pre- and Postwelding

Resistance Spot Welding

Figure 8.7 Figure 8.8

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 109

A controlled variable may be, for instance, the electrode path, the resistance progress, the
welding current or the welding voltage.

Figure 8.10 shows the principle structure of a resistance spot welding machine. The
main components are: the machine frame, the welding transformer with secondary lines, the
electrode pressure system and the control system. This principle design applies to spot, pro-
jection and roller seam welding machines. Differences are to be found merely in the type of
electrode fittings and in the electrode shapes.

Fel
welding current
electrode force

5 Iw tpre = pre-weld time

tw = welding time 1
th = holding time
tpres = pressure time

9
tpre tw th time 2
tp res 10

3
6
Fel 11 12
welding current
electrode force

4
5 Iw
7 8
7
5

8
time

1 - initial force
1 3 Fel 2 - welding pressure 1 electrode force cylinder
2 pneumatic equipment
welding current
electrode force

force
2 Iw 3 - post pressure force 3 machine tool frame
5 4 - preheating current 4 welding transformer
5 - welding current 5 power control unit
4 6 6 current conductor
7 8 6 - postheating current
7 lower arm
7 - ascending current
8 foot switch
8 - descending current 9 top arm
10 electrical power supply cable
time 11 water cooled electrode holder
br-er8-09e. cdr © ISF 2006 12 electrode
br-er8-10e.cdr © ISF 2002

Course of Force and Current Schematic Assembly of

Spot Welding Machine

Figure 8.9 Figure 8.10

Figure 8.11 depicts the possible process variations of resistance spot welding. These are
distinguished by the number of plates to be welded and by the arrangement of the electrodes
or, respectively, of the transformers. It has to be noted that with a corresponding arrange-
ment also plates can be welded where one of the two plates has a non-conductive surface
(as, for example, plastics).

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 110

Figure 8.12 shows the current types which are normally used for resistance welding.
Alternating current has the
~

simplest structure (Figure

8.13) and is most price ef- ~ ~

fective, unavoidable are,

however, the disadvan- two-sided single-shear two-sided two-shear one-sided single-spot welding
single-spot welding spot welding (stack welding) with contact electrode
tages of current zeros and ~ ~ ~

weld nugget cooling. In +

+ + +
relation to the average cur- +

rent values, peak loads ~

two-sided duplex spot one-sided duplex spot welding one-sided multi-spot welding
occur and, with that, in- welding with conductive base with conductive base
br-er8-11e.cdr © ISF 2002

creased electrode wear.

Variants of Spot Welding
These extreme peak loads
do not occur with direct Figur 8.11
current.

The structural design of a d.c. supply unit is, however, more complicated and, therefore,
more expensive than an a.c. supply unit.
As conventional welding machines operate with a 50 Hz primary current supply, the welding
current can be controlled only in 20 ms units (1 period). When the inverter-direct current
technique or, respectively, the medium-frequency technique is used, a finer setting of the cur-
rent-on period and a more
alternating current medium frequency direct current
20 12 precise control of the weld-
15
10
[kA]

[kA]

10
5 8 ing current is possible.
0
current

6
current

0.00 0.02 0.04 0.07 0.09 0.11 0.13 0.16

-5
4
-10
-15 2

-20 0
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16
In order to realise higher
welding time [s]
welding time [s]
"conventional" direct current impulse capacitor current
currents and shorter weld-
18 45
16 40 ing times, the impulse ca-
[kA]
[kA]

14 35
12 30
25 pacitor resistance welding
current

10
current

8 20
6 15
4 10 technique is applied. The
2 5
0 0
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 rectified primary current is
welding time [s] welding time [s]
br-er8-12e.cdr © ISF 2002

stored in capacitors and,

Current Types
through a high-voltage
Figur 8.12 transformer, converted to

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 111

high welding currents. The

single-phase static-inverter direct current
advantages of this tech- alternating current

nique are low heat input

and high reproducibility.
Because of the high energy
density, materials with
3-phase direct current capacitor impulse discharge
good conductivity can be
welded and also multiple-
projection welds can be
carried out. A disadvantage
br-er8-13e.cdr

of this method is, apart

from the high equipment
costs, the difficult regula- Figure 8.13
tion of the welding current.

Electrodes for spot resistance welding have the property of transferring the electrode force
and the welding current. They are wearing parts and, therefore, easily replaceable.

requirements

- good electrical conductivity

- good thermal conductivity
- high high-temperature strength
electrodes - high temperature stability
- high softening temperature
form A form B form C form D - little tendency to alloying with workpiece material
- easy options in machining

ISO 5182 ISO 5182

form E form F form G Key Key
Group Type No. Group Type No.

1 Cu - ETP 10 W75 Cu
1
electrode caps 2 Cu Cdl
11 W78 Cu
1 Cu Crl
2
2 Cu Crl Zr 12 WC70 Cu
B
1 Cu CO2 Be 13 Mo
A 3
2 Cu Ni2 Si
14 W
1 Cu Ni1 P

2 Cu Be2 Co Ni 15 W65 Ag
4
3 Cu Ag6

CuAl10NiFe5Ni5
4

electrode holders
br-er8-14e.cdr © ISF 2002 br-er8-15e.cdr

Electrodes, Electrode Materials

Electrode Caps and Holders

Figure 8.14 Figure 8.15

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 112

Depending on the shape and type of electrode, solid electrodes or electrode caps, must
be either remachined or recycled. Figure 8.14 depicts various types of electrodes, electrode
caps and holders.

Dependent upon the electrode application, different alloyed electrode materials are used,
Figure 8.15. The added alloying elements influence the red hardness, the tempering resis-
tance, the conductivity, the fusion temperature, the electrode alloying tendency, and, finally,
the machinability of the electrode material. When beryllium is used as an alloying element,
the admissible MAC values must be strictly adhered to during remachining or dressing of the
electrodes.

Already during the design phase of the components to be welded, importance must be at-
tached to a good accessibility of the welding point. Moreover, the electrode force which is
imperative to the process must be applied in a way that no damage is done to the workpiece.
In the ideal case, the welding point is accessible from the top and from below, Figure 8.16.

poor good poor good

br-er8-16e.cdr © ISF 2002 br-er8-17e.cdr

© ISF 2002

Accessibility for Spot Contact Area for

Welding Electrode Spot Welding Electrodes

Figure 8.16 Figure 8.17

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 113

In order to avoid the displacement of the elec-

trodes, the electrode working surface must
be flat. Also during the design phase space
must be provided for an adequately large

spot welding
clearing zone around the working point, in
A order to guarantee the unimpeded electrode
approach to the working point, Figure 8.17.
shunt connection current

Dependent on the joining job, the process

current path copper

indirect welding
variation, or the resistance welding method, a
one side
so-called “shunt current/effect” may be no-
ticed. This current component, as a rule, does
not contribute to the formation of the weld
nugget; under certain circumstances it might
roller seam welding
br-er8-18e.cdr
even prevent a reliable welding process. In
Shunting the example, shown in Figure 8.18, the shunt

Figure 8.18
Welding spatter:
Discharge of molten material between two steel
current leads to undesired fusing contacts sheets or from the surface of steel sheets.

and, because of the lacking electrode force at

this point, also to damages to the plate sur-
face.

If unsuitable welding parameters have been

fig. 1 fig. 2
set, weld spatter formation may occur, Fig-
Reason here is high welding current, (fig. 1) or
ure 8.19. Liquid molten metal forms on the too-small edge distance (fig. 2)

plate surface or in the joining zone. The rea-

sons for this kind of process disturbance are,
for example, too low an electrode force with
regard to the set welding current or welding porosity in the joint caused discharge of molten
by welding spatter material at the joint plane
time, too high an energy input with regard to br-er8-19e.cdr

the plate thickness or too small an edge dis- Welding Spatter

tance of the welding point.

Figure 8.19

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 114

Figure 8.20 shows a list of

welding current changes
a large number of possible
secondary
shunt wear of wear of mains voltage
connection electrodes cable fluctuation
electrical
impedance
disturbances in resistance
spot welding. Welding cur-
alteration to force

welding equipment
alteration
Qeff = Qinput - Qlosses wear
of rent changes are caused
pressure
Qeff
by: shunt, electrode wear,
diversion
plate
heat cable wear, mains voltage
variations, secondary im-
plate quality number plate edge
thickness of plates of plates surface distance
pedance.
modification of the unit
br-er8-20e.cdr

Different welding condi-

tions are caused by weld-
Figure 8.20 ing machine wear, different
heat dissipation. Non-
uniform conditions by alterations to components are: different plate thicknesses, plate quality,
number of plates, plate surfaces, edge distances. Electrode force changes are caused by:
pressure fluctuations and -changes, plate bouncing.

The resistance spot welding method allows

materials weld-
welding of a large number of materials. A list ability alloying good sufficient
elements weldability weldability
of the various materials is shown in Figure aluminium satisfactory
maximum content [%]
iron very good
8.21. The alloying elements which are used
gold satisfactory C 0,25 0,40
for steels have a varying influence on the suit- cobalt very good C + Cr 0,35 1,60
C + Mo 0,50 0,70
copper poor
ability for resistance spot welding. The values C+V 0,40 0,60
magnesium good
C + Mn 1,40 1,60
which are indicated in the table are valid only molybdenum satisfactory C + Ni 3,00 4,00
nickel very good Si 0,40 1,00
when the stated element is the sole alloying Cu 0,60 0,60
platinum very good
constituent of the steel material. silver very good
P+S 0,10 0,10
C+Cr+Mo+V 0,60 1,60
tantalum very good
titanium very good
Figure 8.22 shows a comparison between tungsten satisfactory

resistance spot and resistance projection

influence of
alloying elements
welding. The fundamental difference between weldable materials (steel materials)

the two methods lies in the definition of the br-er8-21e.cdr

current transition point. Weldable Materials

Figure 8.21
2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 115

The differences between both methods are illustrated in Figure 8.23. The short life of the
electrodes used for resistance spot welding is explained by the higher thermal load and the
larger pressing area caused by the smaller electrode contact areas. The term “electrode life”
stands for the number of welds that can be carried out with one pair of electrodes without
further rework and without
exceeding the tolerances before welding after welding

for quality criteria of the

weld.

Depending on the de-

follow-up
mands on the joint strength distance

or on the projection rigidity,

elektrode
different projection shapes
are applied. These are an- projection
br-er8-22e.cdr

nular, circular or longitudi-

nal projections. The weld-
ing projections are, accord- Figure 8.22

spot projection embossed solid natural

welding welding projection shape projection shape projection shape

elektrodes: struck
pressed machined
diameter up to 20 mm > 20 mm
cut
tip face convex flat mould pressed
pushed
electrode life less longer

place where circular spot

the nugget circular
originates longitudinal contact
elektrodes projections longitudinal
annular line
annular
interrupted annular contact
number of
one several
welding nuggets

Circular
follow-up distance small big weld nut crossed wires

problems: Longitudinal cut wire-plate

current distribution no yes

force distribution no yes

Annular pushed bolt-pipe

br-er8-23e.cdr © ISF 2002 br-er8-24e.cdr

Differences Between Resistance Customary Projection Shapes

Spot and Projection Welding

Figure 8.23 Figure 8.24

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 116

ing to their size, adapted to the used plate

thickness and may, therefore, appear as dif-
die die

plate
ferent types in the workpiece: embossed pro-
plate
jections, solid projections and natural projec-
tions. The survey is shown in Figure 8.24.
d1
mould plate
d1
mould plate counter-die In Figure 8.25 the production of embossed

embossed projection ring projection

projections in different shapes is shown. The
shape is embossed onto the plate surface by
die appropriate die plates, dies and, if necessary,
l b
counter dies.
mould plate plate
Various problems occur in projection weld-
ing caused by the welding of several joints in
longitudinal projection a single working cycle. Due to different current
paths - when using direct current - and a cur-
br-er8-25e.cdr © ISF 2002

Production of
Embossed Projection Shapes rent displacement - when using alternating
current -, welding nuggets with differing quali-
Figure 8.25

alternating current distribution

intensity of current increases from the center to
the outer area caused by current displacement
force distribution of a C-frame projection press
welder during bending of machine tool frame

direct current distribution

intensity of current decreases from the center to force distribution of a C-frame projection press
the outer area caused by the longer current path welder with non-parallel positioning tables
br-er8-26e.cdr © ISF 2002 br-er8-27e.cdr © ISF 2002

Problem of Current Distribution Problems of Force Distribution

During Projection Welding During Projection Welding

Figure 8.26 Figure 8.27

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 117

ties are produced when no preventive remedies are taken, Figure 8.26.

A varying force distribution,

as shown by the example
in Figure 8.27, also leads
to differing qualities of the
produced weld nuggets.

In Figure 8.28 several ex-

amples of application using
projection welding are de-
br-er8-30e_sw.cdr © ISF 2002
picted. In this example, the

Application Examples of Projection Welding

shapes are of the em-
bossed type.
Figure 8.28

Figures 8.29 and 8.30 show several process variations of roller seam welding. Seam welding
is actually a continuous spot welding process, but with the application of roller electrodes. In
contrast to resistance spot welding the electrodes remain in contact and turn continuously
after the first weld spot has been produced. At the points where a welding spot is to be pro-
duced again current flow is
initiated. Dependent on the
lap joint lap joint with lap joint squash seam butt weld
wire electrode with foil weld with foil
electrode feed rate and on
the welding current fre-
before quency, spot welds or seal
welding
welds with overlapping
weld nuggets are pro-
duced. The application of
after d.c. current also produces
welding
seal welds.
br-er8-28e.cdr © ISF 2002

Roller Seam Welding

Figure 8.29

2005
8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding 118

interrupted-current roller seam weld

overlap seal weld

continuous D.C. seal weld

br-er8-29e.cdr © ISF 2002

Weld Types for Roller Seam Welding

Figure 8.30

2005