Spot Welding

Spot Welding
Lesson Objectives Learning Activities
When you finish this lesson you will 1. View Slides;
understand: 2. Read Notes,
Basics of Resistance Welding Processes 3. Listen to lecture
Heat Generation & Control 4. View Demo
Spot Welding Process and Applications 5. Do on-line
workbook

Keywords: Resistance Spot Welding, Heat Generation,

Equipment Control, Contact Resistance, Upslope, Downslope,
Hold Time, Temper, Squeeze Time, Electrode
 Definition of Resistance
Welding
Resistance welding is a fusion welding process in
which coalescence of metals is produced at the
faying surfaces by the heat generated at the joint by
the resistance of the work to the flow of electricity.
Force is applied before, during, and after the
application of current to prevent arcing at the work
piece.
Melting occurs at the faying surfaces during
welding.
Principal Types of Resistance Welds
Electrodes Electrodes Electrodes Projection
or Welding or Welding or Dies Welds
Tips Wheels

Spot Weld Seam Weld Projection Weld

Electrodes or Dies

Upset Weld Flash Weld

After Welding After Welding

[Reference: Resistance Welding Manual, RWMA, p.1-3]
Typical Equipment of Resistance Spot Welding

(a) (b)
[Reference: Welding Process Slides, The Welding Institute]
Advantages of Resistance Spot
Welding
Adaptability for Automation in High-Rate
Production of Sheet Metal Assemblies

High Speed

Economical

Dimensional Accuracy
 Limitations of Resistance Spot
Welding
Difficulty for maintenance or repair
Adds weight and material cost to the product, compared with
a butt joint
Generally have higher cost than most arc welding equipment
Produces unfavorable line power demands
Low tensile and fatigue strength
The full strength of the sheet cannot prevail across a spot
welded joint
Eccentric loading condition
 Resistance Welding
Resistance welding depends on three
factors:
Time of current flow (T).
Resistance of the conductor (R)
Amperage (I).
Heat generation is expressed as
Q = I2R T, Q = Heat generated.
 Heat = I2 RTK

Where
Is a function of:
I = Current (Amps) Transformer Tap Setting
R = Resistance (Ohms) Material Prop., & Pressure
T = Time (Cycles 1/60 Control Setting
Second)
K = Heat Losses Conduction, Convection,
Radiation
Heating Value of Current = RMS Current

Irms=0.707 Ipeak
 Block Diagram of Single-Phase
Spot Welder
Contactor

Main Power Line

Spot Weld
N=np/ns

Vs= Vp/N

Is = Ip N
 Heat = I2 RTK

Where
Is a function of:
I = Current (Amps) Transformer Tap Setting
R = Resistance (Ohms) Material Prop., & Pressure
T = Time (Cycles 1/60 Control Setting
Second)
K = Heat Losses Conduction, Convection,
Radiation
Contact-Resistance Measurement
Electrode Force

Rec
Small Current Rec = contact resistance
Rec between electrode
and sheet surface
Rsc Rv
Rtotal Rsc = contact resistance
Rec Rv at the faying surface

Rv = volume resistance of
Contact the sheets
Area
Rec
Electrode Force
Factors Affecting Heat
Generation (Q):
Welding pressure
as welding pressure increases both R
and Q decrease.
Electrodes
deformation of electrodes increases
contact area. As contact area increases,
both R and Q decrease.
Link to electrode force demo
(a) Pickled Conditions
Surface Condition
Steel

Steel

Resistivity
(b) Rusted Conditions
Steel Rusty
Oils/Dirt Polished
Oxide
Pickled

Oxide Electrode Force

Oils/Dirt

Steel
 Resistance Varies with Pressure

Low Pressure Medium Pressure High Pressure

(a) (b) (c)

Volume-Resistance Measurement
Electrode Force

Small Current Rec = contact resistance

Rec between electrode
and sheet surface
Rsc Rv
Rtotal Rsc = contact resistance
Rec Rv at the faying surface

Rv = volume resistance of
Contact the sheets
Area
Rv
Electrode Force
 Resistivity as a Function of Temperature

130
120
110 HSLA
Resistivity, -cm

100
90
80
70
60 Low Carbon
50
40
30
20
10
100 200 300 400 500 600 700 800
Temperature, C
[Reference: Welding in the Automotive Industry, D.W. Dickinson, p.125]
 Heat = I2 RTK

Where
Is a function of:
I = Current (Amps) Transformer Tap Setting
R = Resistance (Ohms) Material Prop., & Pressure
T = Time (Cycles 1/60 Control Setting
Second)
K = Heat Losses Conduction, Convection,
Radiation
Heating Value of Current = RMS Current

Irms=0.707 Ipeak
 Upslope/Downslope, Hold Time,
& Temper
Electrode
Pressure

Weld Current
Current

Temper Current

Upslope Downslope Temper

Squeeze Time Weld Time Off Time Hold Time
 Heat = I2 RTK

Where
Is a function of:
I = Current (Amps) Transformer Tap Setting
R = Resistance (Ohms) Material Prop., & Pressure
T = Time (Cycles 1/60 Control Setting
Second)
K = Heat Losses Conduction, Convection,
Radiation
 Heat Dissipation
Water-Cooled Copper Alloy Electrode

Base Metal
Weld Nugget
Base Metal

Water-Cooled Copper Alloy Electrode

 2
Heat = I RTK

Where
Is a function of:
I = Current (Amps) Transformer Tap Setting
R = Resistance (Ohms) Pressure
T = Time (Cycles 1/60 Control Setting
Second)
K = Heat Losses Conduction, Convection,
Radiation

Lets put it all together

Initial Resistance Through Weldment

Top Electrode
Water
Weld
Nugget

Distance

Resistance
Bottom Electrode
 Temperature Readings of A Spot Welding Process
(Note: Temp at Electrode Sheet Interface Higher than Bulk)

Workpiece

This illustration was taken

about 4/60th of a second
after the welding current
starts.
 Temperature Distribution

Temperature
distribution
at
various Electrode At the end of
location welding time After 20%
welding time
during
welding.
Workpiece

Electrode

Temperature
Link to nugget growth demo
Nugget Solidification