plates to create a weld joint.

It is named as
resistance welding because it uses electric
resistance to produce heat. It is a very
efficient pollution free welding process but its
applications are limited due to its high
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Resistance
Welding - Spot,
Seam, Projection
F E AT U R E D P O S T

18 Mechanical Properties Which

and Flash Welding: Every Mechanical Engineer Should

Know

Principle:
All resistance welding like spot welding, seam
welding, projection welding etc. are worked on
same principle of heat generation due to
electric resistance. When a current passes
through electric resistance, it produces heat.
This is same principle which is used in electric
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on resistance of material, surface conditions,
current supplied, time duration of current
supplied etc. This heat generation takes place
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I = Electric current in ampere What Is Engine? What Are Main
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R = Electric resistance in Ohm Today We Will Discuss About
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T = Time of current flow in second Used In Automobile. Any Device
Which Can Convert Heat Energy
Of Fuel Into Mechanica...
This heat is used to melt the interface metal to Main Parts Of An Internal
Combustion Engine
form a strong weld joint by fusion. This Today We Will Learn About
process produces weld without application of Main Parts Of An Engine. An
Internal Combustion Engine Is
any filler material, flux and shielding gases. The Engine In Which
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There are four main type of resistance
welding. These are Types Of Clutches
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Types Of Clutches Used In
Automobile Industries. In An
Automobile , The Engine
Spot Welding: Produces Power And This
Powe...

It is simplest type of resistance welding in Lathe Machine: Main Parts,

Operation And Working
which the work pieces are held together under Today We Will Learn About
pressure of anvil face. The copper electrodes Lathe Machine Parts, Its
Operation And Working. Lathe
are brought in contact with work piece and Machine Is A Basic Machine
Which Is Used In Every Metal Fo...
current start to flow through it. The work piece
material applies some resistance in flow of
current which cause local heat generation. At
the interface surfaces the resistance is high
due to air gap. The current start to flow
though it which melt down the interface
surface. The amount of current supply and
time should be sufficient for proper melting of
interface surfaces. Now the current stopped to
flow but the pressure applied by electrode
maintained for a fraction of second, while the
weld rapidly cooled. After it, the electrodes
remove and brought to contact at other spot.
It will create a circular nugget. The nugget
size depends on size of electrode. It is
generally about diameter 4-7 mm.
Seam Welding:

Seam welding is also called continuous spot

welding in which a roller type electrode is used
to flow current through work pieces. First the
rollers are brought in contact with work piece.
A high ampere current is passed through these
rollers. This will melt the interface surfaces
and form a weld joint. Now the rollers start
rolling at work plates. This will create a
continuous weld joint. The timing of the weld
and movement of electrode is controlled to
assure that the weld overlap and work piece
does not get too hot. The welding speed is
about 60 in/min in seam welding. It is used to
create air tight joints.
Projection Welding:

Projection welding is same as spot welding

except a dimple is produced on work pieces at
the location where weld is desired. Now the
work pieces held between electrode and a
large amount of current pass through it. A
small amount of pressure is applied through
electrode on welding plates. The current pass
through dimple which melt down it and the
pressure causes the dimple flatten and form a
weld.

Flash butt Welding:

It is another type of resistance welding which

is used to weld tubes and rods in steel
industries. In this process, two work pieces
which are to be welded will be clamped in the
electrode holders and a high pulsed current in
the range of 100000 ampere is supplied to the
work piece material. In this two electrode
holders are used in which one is fixed and
other is movable. Initially the current is
supplied and movable clamp is forced against
the fixed clamp due to contact of these two
work pieces at high current, flash will be
produced. When the interface surface comes
into plastic form, the current is stopped and
axial pressure is increased to make joint. In
this process weld is formed due to plastic
deformation.
Application:

Resistance welding is widely used in

automotive industries.
Projection welding is widely used in
production of nut and bolt.
Seam welding is used to produce leak
prove joint required in small tanks,
boilers etc.
Flash welding is used to welding pipes and
tubes.

Advantages and
Disadvantages:

Advantages:

It can weld thin (0.1 mm) as well as thick

(20mm) metals.
High welding speed.
Easily automated.
Both similar and dissimilar metals can be
weld.
 The process is simple and fully automated
so does not required high skilled labor.
High production rate.
It is environment friendly process.
It does not require any filler metal, flux
and shielding gases.

Disadvantages:

High equipment cost.

The thickness of work piece is limited due
to current requirement.
It is less efficient for high conductive
materials.
High electric power required.
Weld joints have low tensile and fatigue
strength.

This is all about resistance welding principle,

types, application, advantages and
disadvantages. If you have any query
regarding this article, asks by commenting. If
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