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
 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
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.
 Resistance Varies with Pressure

Low Pressure Medium Pressure High Pressure

(a) (b) (c)

 Upslope/Downslope, Hold Time,
& Temper
Electrode
Pressure
Current

Weld Current
Temper Current

Upslope Downslope Temper

Squeeze Time Weld Time Off Time Hold Time
 Heat Dissipation
Water-Cooled Copper Alloy Electrode

Base Metal
Weld Nugget
Base Metal

Water-Cooled Copper Alloy Electrode

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
location Electrode At the end of
during welding time After 20%
welding time
welding.
Workpiece

Temperature
Nugget Solidification