DPP D3

LAB REPORT 1

KOLEJ KEMAHIRAN TINGGI MARA

KUANTAN PAHANG

TITLE

JOINING PROCESS: RESISTANCE SPOT WELDING

SESSION: JAN-MAY 2022

NAME

MATRIX NO 19259 SEMESTER 4

DMA20052 – AUTOMOTIVE
CODE & SUBJECT
COMPONENT MANUFACTURING
LECTURER / VTO EN. MUHAMAD HAFIZ BIN REKMAN
SUBMISSION DATE

1
 DPP D

OBJECTIVE

1. Demonstrate resistance spot welding process

2. Use resistance spot welding machine

3. Determine welding quality of resistance spot welding

INTRODUCTION

2
 DPP D
TOOLS AND EQUIPMENT:
1. Resistance spot welding machine (press type)
2. Sheet metal pieces
3. Mallet
4. Chisel
5. Plier

PROCEDURE

1. Switch on the circuit breaker of machine and coolant switch.

2. Switch on the welding machine.
3. Ensure the machine is in good condition.
4. Clean up the electrode from weld spatter.
5. Prepare two pieces of sheet metal in regular size for handling.
6. Hold the sheet metals in overlapping position.
7. Put the sheet metal in between upper and lower electrode and hold the sheet metal gaps.
8. Press the foot treadle by feet to close the welding electrode and start the squeezing
stage.
9. Hold the pressed foot treadle until welding and holding time done to complete the welding
process.
10. Release the foot treadle to release the welding electrode from holding the workpiece.
11. Determine the quality of welding by visual observation.
12. Clean the machine and equipment.
13. Keep good housekeeping in workshop.
14. Prepare the specimen for destructive testing of spot welding (peel test and chisel test).
15. Conduct the testing manually until the welding fail and fracture occur.
16. Observe the type of fracture at spot welding area.

3
RESULT

Results:
Type of test Current Holding Observation Comment
Level Time, t Material Welding
(1,2,3) (s)
Peel Test 1 3 2 Fail Success Strong weld
Peel Test 2 3 3 Fail Success Stronger weld
Peel Test 3 3 1 Success Fail Weak weld
Chisel Test 1 3 2 Fail Success Strong weld
Chisel Test 2 3 3 Fail Success Stronger weld, material
damage
Chisel Test 3 3 1 Success Fail Weak weld, easily
separate

DISCUSSION

1. What are the advantages of resistance spot welding compared to other fusion welding
type?
 In this type of welding the base metal does not undergo to large heat affected area.
 This type of welding is an easy process.
 Spot welding has a high production rate.
 Spot welding can be applied to different metals to join.
 Spot welding is a low-cost process.

2. What are the limitations of resistance spot welding?

 Only thin metals can be welded accurately and efficiently.
 Installment cost is more.
 This type of welding gets deformed.
 Changes in power supply leads to weak welding.

3. Determine the characteristics of good welding of resistance spot welding.

4. Give the effect of low and high of squeeze time.

5. Give the effect of low and high of welding time.

6. List 5 location in automotive component required resistance spot welding.

I. Door frames
II. Fenders
4
III. Car doors
IV. Hoods
V. brackets

CONCLUSION

REFERENCE

References:
1. https://www.intran.mx/automotive-spot-welding-popularity/
2. https://www.mechanicaleducation.com/2019/04/advantages-and-disadvantages-spot-
welding.html
3. https://en.wikipedia.org/wiki/Spot_welding
4. https://www.twi-global.com/technical-knowledge/faqs/what-is-spot-
welding#:~:text=Spot%20welding%20(also%20known%20as,current%20to%20the
%20weld%20area.