Spot Welding

Types of Welding
Welding
Process

Arc

Spot

Resistance

Seam

Projection

Gas

Flash

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.

Spot Welding...

In Spot Welding the pieces to be joined are

clamped between two electrodes under force ,
and an electrical current is sent through them.
Force is applied before, during, and after
the application of current to prevent arcing at
the work piece.
In spot welding fusion of faying surfaces of a
lap joint is achieved at one location by
opposing electrodes

Typical Equipment of Resistance Spot Welding

Spot Welding Machines

Advantages of Resistance Spot

Welding

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
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses =0.23

Is a function of:
Transformer Tap Setting
Material Prop., & Pressure
Control Setting
Conduction, Convection,
Radiation

Which materials can be welded by

spot welding?
Spot welding can be used for joining many ferrous and
non-ferrous alloys. The materials that are more easily
welded by this process, are low alloy and steel, stainless
steel, Aluminium and light-alloys, nickel and its alloys,
galvanized sheets, brass and copper can also be welded.