Spot Welding
Spot Welding
Spot Welding
Resistance Spot welding is the process of joining two thin metal sheets together by applying
pressure. The heat required for welding is generated by the resistance to the flow of current
through the electrode. The welding electrodes are made up of copper which is a good
conductor of electricity. The movable and fixed electrodes of the spot welding machine are
held under pressure on either side of pair of plates to be welded together as the current
passes it experiences the resistance between the electrode and workpiece contact and
generates heat
This heat causes the interface of the workpiece in contact with another workpiece to melt
and pressure fuses the two metals thus forming a solid bond. The equipment required in
spot welding machines also known as electrodes. Coming to the working of spot welding,
When the power is turned ON the transformer supplies the low voltage, and high current to
the electrodes made up of copper these electrodes, are held under pressure against a pair of
workpieces to be spot welded with the help of tongs.
The current flows from the tongs to the electrodes as copper is a good conductor of
electricity but faces resistance at the point of contact between the two work pieces. This
resistance generates heat at metal to metal interface and causes the two metals in contact to
melt. Then the pressure causes the molten metal to fuse together and thus a solid bond is
formed.
The brief overview of spot welding is studied, let us look at the advantages and
disadvantages:
o This process is simpler with no filler metal the process can be automated and this
process is simple, no filler metal is required.
o Low and no fumes are generated during the process
o High welding rate is possible
Seam welding
Resistance Seam welding, the workpiece is supported on both sides by a pair of electrodes
are in the form of rollers to produce a continuous weld on the workpiece continuous spot
welding is known as seam welding. And the working principle of seam welding is similar to
that of resistance spot welding equipment are components used in the process of seam
welding when the power is turned ON the transformer supplies the low voltage high current
to the roller electrodes made up of conductive materials.
o Welding transformer
o Paint containers welding of gasoline tanks
o Automobile mufflers
o Welding of sheet metal tanks
o This process is suitable for thin sheets only up to a thickness of three millimeters
since the electrodes are in the form of rollers they can weld only along a straight line
or well-curved path the process is limited to the lap joints.
Projection welding
It is one type of resistance welding process wherein coalescence is produced by the heat
obtained from resistance to electric current flow through work parts held together under
pressure by electrodes. These electrodes are cooled as in spot welding. Since a number of
welds are made at each operation, both the electrical power (kVA) and mechanical pressure
must be correspondingly greater as compared to spot welding.
Fig : Resistance Projection welding diagram
The projection in the upper pieces is held in contact with the lower pieces under electrode
pressure. The current flows and is localized to the region around the projection, heating the
metal in that area to the plastic state. The heated and softened projection collapses under
the pressure of the electrodes thereby forming the weld. Flat electrodes are used against tip
electrodes in spot welding.
Step 1: One part to be welded is placed in a rotor-driven chuck and the other part is held
stationary. Now the rotor is switched on to rotate at a very high speed along with the
workpiece.
Step 2: The rubbing of welding surfaces creates sufficient heat (of the order of 900-
13000 C for steel). Now a high pressure is applied through the stationary part.
Step 3: Once the temperature of the welding surfaces reaches the required temperature,
the rotor is stopped.
Step 4: Now, the pressure is increased continuously till both parts weld to each other.
Benefits of Friction Welding
Friction welding provides various advantages with respect to conventional welding
processes. Some of the advantages of using friction welding are:
Joining Dissimilar Materials: Friction welding allows to join of aluminum with steel or
copper to aluminum. Similarly, various bi-metallic friction welded joints can be produced.
No external heat source or flux application
Fast and efficient process
Need very less surface preparation
As the welding process is CNC controlled, the friction welding process produces
consistent quality products.
Reduced Material wastage
Environment-friendly process
As solid-state welding, friction welding avoids defects associated with fusion welding.