Resistance Welding

Submitted to Submitted by
Mrs. Neeti mari Yogesh Tewatia
H.O.D. T.L .Chaud ME07066
 Resistance welding
Resistance welding (ERW) refers to a group of welding
processes such as spot and seam welding that produce
coalescence of faying surfaces where heat to form the weld is
generated by the resistance of the welding current through
the work pieces. Some factors influencing heat or welding
temperatures are the proportions of the work pieces, the
electrode materials, electrode geometry, electrode pressing
force, weld current and weld time. Small pools of molten
metal are formed at the point of most electrical resistance
(the connecting surfaces) as a high current (100–100,000 A)
is passed through the metal. In general, resistance welding
methods are efficient and cause little pollution, but their
applications are limited to relatively thin materials and the
equipment cost can be high.
 Projection Welding
Projection welding has fewer variables that affect the resistance welding process as
compared to spot welding. The most important variables of this assembly technique are
the quality of the projections and the response of the cylinder as the projection collapses
during the welding time.
 Spot welding
 Spot welding is a resistance welding method used to join two to four overlapping metal
sheets which are up to 3 mm thick each. In some applications with only two overlapping
metal sheets, the sheet thickness can be up to 6 mm. Two copper electrodes are
simultaneously used to clamp the metal sheets together and to pass current through the
sheets. When the current is passed through the electrodes to the sheets, heat is generated
due to the higher electrical resistance where the surfaces contact each other.
 Seam welding
Seam welding is the act of welding two similar metals together at a seam, usually on a
piece of automated equipment. This process differs from butt welding, as that is
generally a process that is done on static (non-moving) metals.
 Flash welding
 Flash welding is a type of resistance welding that involves pressing
two ends together, while simultaneously running a current between
them. This has the effect of forming a joint between the two metals
that is free of oxides as the surfaces of the two joining parts is forced
out the sides of the joint and is known as flash, hence the name.
 Upset welding
 Upset welding is a special way of welding, in which two
pieces of material are forged together at elevated
temperatures. There are different ways to reach this
temperature, but a current through the interface, friction or
sometimes an external source are used.
 Safety Factors
 Welding can be extremely dangerous with
the use of large amounts of current and
heat. Always be sure to clamp the
electrodes tightly, protect your eyes from
the intense light given off in the welding
process and protect your hands because the
workpiece can get very hot during welding.
Take all safety precautions necessary
before, during and after spot welding.
THANK YOU