Resistance Spot Welding (RSW)

Introduction

Resistance spot welding utilizes the resistance offered by the material for the flow of

current. The electrical energy is converted into the heat energy to obtain the welded joint. In

resistance spot welding no arc/flames or gases are used. Therefre, it can also be termed as a

green technique for metal joining. The sheets are welded together due to electrical resistance
developed at the interface surfaces, which are held under pressure by conductive electrodes. The

heat is generated due to electrical resistance hence the interface melts over a spot and forms the

weld. In this welding process, the overlapping sheets are positioned between the water-cooled
electrodes, and then the heat is obtained by passing a sufficient electrical current for a short

period of time. So, it can be said that in resistance spot welding, the individual welds are
produced by momentary application of pressure and resistance into the workpiece. The sheets are
held together under pressure betiween faces of the electrodes. Resistance spot welding is a widely
used joining process for welding sheet metal assemblies in automobiles, truck cabins, rail
vehicles and home applications due to its advantages such as welding efficiency and suitability

for automation.

Principle of Resistance Spot Welding

The first requirement in the sequence of operations is to develop sufficient heat to raise a

particular spot of metal to the molten state. This process uses the "Ohmic Heating principle".

1. shows the basic principle of resistance spot welding, in which the source of electrical
Figure
This load is basically in the form of a resistor called as
energy is connected to a load.
resistance(R). When the voltage (V) is applied across this load causes current(I) to flow through

the workpieces and developed resistance at the interface. So, this is a simple electrical circuit, in

which the voltage V is applied through the load R, and allows the current to flow. Then the heat

offered against the flow of current at the interface between

(H)is developed due to resistance
workpieces to be welded. The developed heat melts the interface metal and the fused interface

metal is allowed to cool under pressure until it has adequate strength to hold the workpieces

together. For the strong weld, the coordinated application of electric current and mechanical
pressure of sufficient magnitude and duration(T) is always required. So, it can be said that the
amount of heat produced is a function of current, time, and resistance between the parts to be

welded. This is the basic principle being used in this process. The machine is started which

applies current and the resistance is generated at the point of contact. The nuggets are roughly

elliptical at the interface. They can be overlapped to produce an essentially continuous weld

joint.
PRESSURE

ELECTRODE

WELD Pl

M
SUPPLY
WORK R
PIECES
P2

TRANSFORMER

Figure 1.Principle of resistance spot welding

The heat generated in resistance welding is given by the equation:

H= KI RT
where, H= Heat genrated in Joules

K Constant
I=Current in Amperes

R =resistance of the Joint in Ohm

T Time of flow of current in second

Spot Welding Time Cycle

should be optimized in order to get
of the resistance spot welding
The process parameters
spot welding parameters will produce strong
combination of the
good quality joints. The suitable
joints and have
ve good quality of weld. The resistance
a
Darameters includes
spot welding par
olectrode force, diameter of the electrode, contact surface
condition, squeeze time, weld time
hold time and weld current. Generally the
welding cycle for spot welding consists of the rour
hasic phases, squeeze time, weld time, hold time, and off time.
Figure 2. the
depicts timecycle
during resistance spot welding. The phasesof the welding cycle are described as follows
SQUEEZE HOLD HOLD OFF

PRESSURE ON CURRENT PRESSURE

APPLIED OFF RELEASED

Figure 2. Cycle time for spot welding

1. Squeeze Time: This is the time interval between initiating the timer and the first application
of current or the time between pressure application and weld.

2. Heat or Weld Time: The time required for welding current to be applied though the

workpieces for making joint. This is termed as the weld time in cycles.
3. Hold Time: Time that pressure is maintained after weld is made. It is the tinme required during
ends.
which force is maintained on the workpieces after the last impulse of current
material for
4. Off Time: This is the time during which electrodes separated to permit moving of
next spot. This term is generally applied when the welding cycle is repetitive.

Resistance Spot Welding Machine:

by Virdi Electrical Works Pvt. Ltd. Delhi is shown in
The resistance spot welding supplied
machine are as follows:
figure. 3. The details about the welding
 Electrodea ooling pipe

Current Control lever Alachine Housing

Foot lever

Figure 3. Resistance spot welding machine

Construction: The unit is of robust construction sturdy heavy rigidly reinforced welded steel
construction. It combines a compact streamlined appearance with maximum resistance to

transformer enclosed in the main frame and is easily accessible, for

mechanical deflection. The

inspection.
sections &
Welding Transformer: Manufactured from high grade materials of copper strips and
continuous temperature rise of 140°C.
water cooled insulation with standing
on primary of the
main transformer
method with 8 tap adjustments
Current Control: By tap
50% to 100% in 8 steps.
having current control from all water cooled with one single
Transformer are
Electrode holders, Arms,
Cooling system:
water-cooling circuit. air eylinder. The
actuated by foot lever or by
electrode is
Electrode Control System: Upper with gauge and
Air system is provided
in both systems.
be calculated lubricator, regulator,
electrode force can easily accessories
such as filter,
All air
calibrated spring.
nanual system with
are
incorporated.
minute.
and speed valve of attaining 60 spots per
gauge, solenoid valve mechanically
capable
Machine is
Maximum Operating Speed:
Technical. he
ecification: The technical
specifications of welding machine are
re
given in the table
.

Table 1. The technical

specilications of resistance spot
s. No.
Machine Model No. welding
UNITS
VSM-20
KVA@s0% Duty Cycle KVA 20
2 Rated Input Voltage
230/415V
3 Transformer Cooling Water Water

4 Water Consumption LPM 10

5 Arms-Diameter mm 64

6 Main Supply Cable Size (mm-) 16/25

7 Current Taps Nos.

Advantages of Resistance Spot Welding:

of sheet metal assemblies
IAdaptability for automation in high-rate production
2.High welding speed
3.Economical
4.Dimensional Accuracy
4.Very short process time
welding rods
solder, or
.NO Consumables, such as brazing materials,

6.0perator safety because of low voltage

1.Clean and environmentally friendiy
formed
8.A reliable electromechanicaljoint is
Limitations of Resistance Spot Welding
compared
with a butt joint
material cost to
the product,
Welght and
equipment
m o s t arc
welding
than
2.Generally have higher cost

3.Low tensile and fatigue strength

 of the sheet
full strength cannot prevail
The

4. across a
spot welded
precautions:
joint
I. Proper aressure should be applied on the electrodes.
lectrode
Correct el diameter needs to be
chosen
2.
depending on the
materialthickness to be
joined.

3. Proper weld time should be selected for welding.

Gloves while doing operation.

4. Use
To prepare a lap Jont on tne given work pieces using spot welding equipment.
GI Sheet
Material required:
naratus required: Spot Welding Equipment, Tongs and Glove, steel ruler, sheet cutter etc.
Procedure:

Figure 4. shows a job prepared using the resistance spot welding. This the single strap resistance
follows:
but welding. Basic steps needed for making the components by RSW are as

between the two electrodes in the

pieces to be joined by spot welding are placed
1. The two

required position.
reference to the thickness
which the current flows through the electrodes with
2. Set the timer for

of the plates towards the fixed

electrode.
movable electrode
moves

lever, so that the

3. Press the foot
on the sheets. the
to develop a pressure short time. Then
4. This causes
joint for a very
current is passed through the
high
. A low voltage and very
welded
and
pressure is squeezed is completed.
metal under electrodes until the job
is repeated
released and the process

'. 1ne pressure is then

 50

50 50

25 25

butt joint
Figure 4. Single strap

to
Mechanical Testing vice jaws. Use
mechanical means

sample in
the resistance spot weld metal with a
metal
Place one end of loose from the parent
the weld should pull
One side of
oce the weld apart. diameter.
weld (nugget)
weld. Check for the
Cxiension from the