Lab Session: 02

Spot Welding

1. Title:

To investigate the effects of varying current, pressure and resistance/pressure on spot welded
specimen.

2. Problem Statement:

Spot Welding is one of the oldest welding processes. It is used in a wide range of industries but
notably for the assembly of sheet steel vehicle bodies, so it is essential to understand the process
properly. It is required to study different parameters involved, SOPs for the utilization of the
equipment and possible hazards encountered while operating the equipment.

3. Objective:

To understand the working principle and basic operating parameters of Spot Welding

4. Theory:

4.1. Introduction:
Resistance Welding is a pressure welding technique using high current and low voltage. The
current passing through the two overlapping workpieces causes local heating and temperature of
the metallic pieces raises to the fusion point due to resistance offered by the workpieces to flow of
current. Subsequent application of pressure results in permanent joining of the workpieces by the
formation of weld without the use of filler material. Workpieces are placed between two rods or
wheels (rolls), which serve as conductor for producing welds. AC electric current is supplied
through copper electrodes or rolls connected to the secondary coil of a welding transformer.
 Figure 1: Schematic of Resistance Welding

Spot Welding is a Resistance Welding (RW) process, in which two or more overlapped metal
sheets are joined by spot welds. The method uses pointed copper electrodes providing passage of
electric current. The electrodes also transmit pressure required for formation of strong weld.
Diameter of the weld spot is in the range 1/8” - 1/2” (3 - 12 mm).

Figure 2: Spot Welding Equipment

4.2. Working Principal:

At Low voltage, high current flowing through the joint generates large amount of heat due to high
contact resistance, which causes melting of joint and further fusion of metals.
Mathematically, the heat generated is given by the formula:
 H = I2RT
I = Current, R = Resistance of the conductor and T = Time of current flow

Figure 3: Spot Welding Simulation

4.3. Equipment:
Schematic diagram of spot welding equipment is as follows:

Figure 4: Spot Welding Equipment Parts

4.4. Welding Parameters:
Note down the readings of current, and time. Take pressure/resistance value of your choice.
Capture and paste the picture of the specimen.
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________

4.5. Defects:
Write down some defects produced in the spot welding.

______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________

4.6. Procedure:
 Prepare the workpieces to be welded by removing any stain or dust particles.
 Turn on the power supply of the equipment and apply the voltage setting.
 Align the workpieces forming a lap joint, place the point to be welded at the lower fixed
electrode and simply touch without any pressure the upper moveable electrode to the
workpiece.
 Slowly apply the pressure through foot switch and remove your foot as spark generates.
 Note down the maximum current from the ampere meter. Also note down from applying
pressure to the point when spark is generated.
 Let the workpieces to cool down for some time.

4.7. Safety Precautions:

The following safety precautions must be observed while working on spot welding setup:
 Always wear lab coat before starting any work.
 Keep a safe distance while operating the equipment.
 Always use goggles while working.
 Proper ventilation must be provided in the shop.
 Keep in mind the location of the fire extinguishers.
5. To Do Assignment:

Observe and study the spot welding process and complete the lab report as per the study
questions given below.
a. What are the other types of resistance welding process?

______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________

b. Discuss the applications of spot welding with their pictures.

______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________

c. What are the advantages and disadvantages of this process?

Advantages:
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________

Disadvantages:
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________