8.

Resistance Spot Welding, Resistance Projection Welding and Resistance Seam Welding

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

105

Figure 8.1 shows an extract from the classification of the welding methods according to DIN 1910 with a detailed account of the conductive resistance pressure welding. In the case of resistance pressure welding, the heating occurs at the welding point as a consequence of Joule resistance heating caused by current flow through an electrical conductor, Figure 8.2. In spot and prowelding

jection welding, the plates to be welded in overlap.

fusion welding

pressure welding

Current supply is carried out through spherical or flat electrodes, respec-

cold pressure welding

resistance pressure welding

friction welding

induction pressure welding

Conduction pressure welding

tively. In roller seam welding, two driven roller elecresistance butt welding flash butt welding

resistance spot welding

projection welding

roller seam welding

trodes are applied. The plates to be welded are mainly overlapped. The heat input rate Qinput is generated by resistance heating in a currentcarrying conductor, Figure

br-er8-01e.cdr

ISF 2002

Classification of Welding According to DIN 1910

Figure 8.1

spot welding workpieces overlap electrode weld nugget

roller seam welding workpiece usually in general overlap driven roller electrode spot rows (stitch weld, roller spots)

projection welding workpieces with elevations (concentration of electicity) workpieces overlap pad electrode several joints in a single weld weld nugget joint

8.3. However, only the effective heat quantity Qeff is instrumental in the formation of the weld nugget. Qeff is composed of the input heat minus the dissipation heat. The heat loss arises from the heat dissipation into the electrodes and the plates and also from thermal radiation.

1 1 3

2 3

4 1 1 1 5

1 electrode force 2 elektrodes 3 production part

br-er8-02e.cdr

4 loaded area

5 projection

Figure 8.2

2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

106

The resistance during resistance heating is composed of the contact resistances on the two plates and of their material resistance. The reduction of the electrode force down to 90% increases the heat input rate by 105%, the reduction of the welding current down to 90% decreases the heat rate to 80% and a welding time reduction to 90% decreases the heat rate to 92%. The time progression of the resistance is shown in Figure 8.4. The contact resistance is composed of the interface resistances between the electrode and the plate (electrode/plate) and between the plates (plate/plate). The resistance height is greatly dependent on the applied electrode force. The higher this force is set, the larger are the conductive crosssections at the contact points and smaller the resistances. The contact surfaces, which are rapidly increasing at the start of welding, effect a rapid reduction of interface resistances.
mOhm

Fel: Qeff: Qinput: I: Q1: Q2 : Q3 : Q4: R(t): Rmaterial(t): Rc(t):

electrode force effective heat total heat input current (time dependence) heat losses losses into the electrodes losses into the sheet metal losses by heat radiation total resistance material resistance contact resistance

Fel

Q4

Q2

Q4

Q3

Qeff

Q3

Qeff = Qinput - Q1l

t=tS

Q4 Q2

Q4

Qinput = C
t=0

I (t) R(t) dt Fel

Q1 = Q2 + Q3 + Q4 R(t) = Rmaterial(t) + Rc(t)

br-er8-03e.cdr ISF 2002

Heat Balance in Spot Welding

Figure 8.3
theoretical contact area 100% metallic conduction contact proportion at room temperature

With the formation of the weld nugget the interface resistances between the plates disappear. During the progress of the weld the material resistance increases from a low value
br-er8-04e.cdr

total resistance

resistance

low electrode force high resistance high electrode force low resistance proportion after first milliseconds welding time
periods

sum of material resistance

sum of contact resistances

10

welding time

surface resistance is collapsed, a3 is highly extended

A1: area out-of-contact A2: contact area with high resistance A3: contact area completely conductive

(surrounding temperatures) to a maximum value above the melting temperature. Figure 8.4
2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding Figure 8.5 shows diaelectrode force resistance rate

107

grammatically the different resistances during the spot welding process with acting electrode force, but without Weld welding nugget current. formation
R5

R1 R3

R3 R6
R6 R7

_ ~

R5 R7 R4 0 100 200

R4 R2

must therefore start in the joining zone because of the existing high contact
br-er8-05e.cdr

R [Ohm]

resistance there. Figure 8.6 shows directly cooled electrodes for resistance welding. The coolant cooling tube, the cooling
10 - 20 6-8

Figure 8.5

cooling tube cooling drill-hole

is normally water. In the water is transported to the electrode base. The diagram shows the temperature distribution in the electrodes and in the plates. The maximum temperature is reached in the centre of the weld nugget and decreases strongly in the

slope
2-5

br-er8-06e.cdr

ISF 2002

Electrode Cooling

Figure 8.6

electrode direction. Sequence of a resistance spot welding process, Figure 8.7: 1->2 Lowering of the top electrode 2->3 Application of the adjusted electrode force Set-up time tpre, sequence 3->4 Switching-on of the adjusted welding current for the period of the welding time tw. Formation of the weld nugget in the joining zone of both workpieces.

2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

108

An example shows the macrosection of a weld nugget after the welding time has ended. 4->5 Maintaining the electrode force for the period of the set post-weld holding time th. 5->6 Switching-off the force generating system and lifting the electrodes off the workpiece. The functions of the set-up time and the post-weld holding time are listed in Figure 8.8. Dependent on the welding task different force and current programs can be set in the welding machines, Figure 8.9. In the top the simplest possible welding program sequence is shown: The application of the electrode force, the set-up time sequence tpre, the switching-on of the welding current and the sequence of the welding time tw, the sequence of the postweld holding time th and the switching-off of the force generating system. The diagram in the centre is almost identical to the one just described. Merely in the welding current range, welding is carried out using an adjustable current rise (7) and current decay (8). The diagram below depicts a more sophisticated current program. In addition, welding is carried out with a variable electrode force (2) and with preheating (4) and post-heating current (6). Dependent on the control system, the process can be influenced by adjustment.
Fel Iw
electrode force Fel

set-up time - compressing the workpiece - build-up of electrode force to preset value - setting-up of reproducible resistance before welding - electrode resting after bounce - preventing resting of electrode on workpiece under electricle voltage

welding current Iw

time t

tpre

tw

th

top electrode

postweld-holding time - holding time of workpiece during cooling of molten metal - prevention of pore formation in the welding nugget - prevention of lifting the electrode under voltage The postweld-holding time has influence on the weld point hardening within certain limits.
br-er8-08e.cdr ISF 2002

workpiece lower electrode weld nugget

insufficiently melted weld nugget

br-er8-07e.cdr

totally melted weld nugget

ISF 2002

Time Sequence of Resistance Spot Welding

Functions of Pre- and Postwelding

Figure 8.7

Figure 8.8
2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

109

A controlled variable may be, for instance, the electrode path, the resistance progress, the welding current or the welding voltage. Figure 8.10 shows the principle structure of a resistance spot welding machine. The main components are: the machine frame, the welding transformer with secondary lines, the electrode pressure system and the control system. This principle design applies to spot, projection and roller seam welding machines. Differences are to be found merely in the type of electrode fittings and in the electrode shapes.

welding current

electrode force

Fel 5 Iw
tpre = pre-weld time tw = welding time th = holding time tpres = pressure time

9
tpre tw tp res th
time

10 6

2 3

welding current

electrode force

Fel 5 7 Iw 8

11

12 4

7 5 8
time 1 - initial force 2 - welding pressure force 3 - post pressure force 4 - preheating current 5 - welding current 6 - postheating current 7 - ascending current 8 - descending current time

welding current

electrode force

1 2 5 7 4 6

3 Iw 8

Fel

br-er8-09e. cdr

ISF 2006
br-er8-10e.cdr

1 electrode force cylinder 2 pneumatic equipment 3 machine tool frame 4 welding transformer 5 power control unit 6 current conductor 7 lower arm 8 foot switch 9 top arm 10 electrical power supply cable 11 water cooled electrode holder 12 electrode
ISF 2002

Course of Force and Current

Schematic Assembly of Spot Welding Machine

Figure 8.9

Figure 8.10

Figure 8.11 depicts the possible process variations of resistance spot welding. These are distinguished by the number of plates to be welded and by the arrangement of the electrodes or, respectively, of the transformers. It has to be noted that with a corresponding arrangement also plates can be welded where one of the two plates has a non-conductive surface (as, for example, plastics).

2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

110

Figure 8.12 shows the current types which are normally used for resistance welding. Alternating current has the simplest structure (Figure 8.13) and is most price effective, unavoidable are, however, the disadvantages of current zeros and weld nugget cooling. In relation to the average current values, peak loads occur and, with that, increased electrode wear. These extreme peak loads do not occur with direct current. The structural design of a d.c. supply unit is, however, more complicated and, therefore, more expensive than an a.c. supply unit. As conventional welding machines operate with a 50 Hz primary current supply, the welding current can be controlled only in 20 ms units (1 period). When the inverter-direct current technique or, respectively, the medium-frequency technique is used, a finer setting of the current-on period and a more
alternating current
20 12
~ ~ ~

two-sided single-shear single-spot welding

~

two-sided two-shear spot welding (stack welding)

~

one-sided single-spot welding with contact electrode

~

+
+
two-sided duplex spot welding
br-er8-11e.cdr

Figur 8.11

medium frequency direct current

[kA]
10 8 6 4 2 0 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16

[kA]

15 10 5 0 0.00 0.02 0.04 0.07 0.09 0.11 0.13 0.16 -5 -10 -15 -20

current

current

welding time [s]

"conventional" direct current

18 16 14 12 10 8 6 4 2 0 0.00 0.02 0.04
br-er8-12e.cdr

45 40 35 30 25 20 15 10 5 0 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16

[kA]

[kA]

current

current

0.06 0.08 0.10 0.12

0.14 0.16

welding time

[s]

Current Types

Figur 8.12

one-sided duplex spot welding with conductive base

one-sided multi-spot welding with conductive base

ISF 2002

Variants of Spot Welding

precise control of the welding current is possible. In order to realise higher currents and shorter welding times, the impulse capacitor resistance welding technique is applied. The rectified primary current is stored in capacitors and, through a high-voltage transformer, converted to

welding time

[s]

impulse capacitor current

welding time

[s]
ISF 2002

2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding high welding currents. The advantages of this technique are low heat input and high reproducibility. materials with Because of the high energy density,
3-phase direct current capacitor impulse discharge single-phase alternating current static-inverter direct current

111

good conductivity can be welded and also multipleprojection welds can be carried out. A disadvantage
br-er8-13e.cdr

of this method is, apart from the high equipment costs, the difficult regulation of the welding current. Electrodes for spot resistance welding have the property of transferring the electrode force and the welding current. They are wearing parts and, therefore, easily replaceable. Figure 8.13

requirements - good electrical conductivity - good thermal conductivity - high high-temperature strength - high temperature stability - high softening temperature - little tendency to alloying with workpiece material - easy options in machining
ISO 5182 Group Type 1 No. 1 2 1 2 1 2 1 4 2 3 4
Cu - ETP Cu Cdl Cu Crl Cu Crl Zr Cu CO2 Be Cu Ni2 Si Cu Ni1 P Cu Be2 Co Ni Cu Ag6 CuAl10NiFe5Ni5

electrodes
form A form B form C form D

form E

form F

form G

Key

ISO 5182 Group Type 10 11 12 B 13 14 15 Mo W No.

Key

W75 Cu W78 Cu WC70 Cu

electrode caps
2 A 3

W65 Ag

electrode holders
br-er8-14e.cdr ISF 2002
br-er8-15e.cdr

Electrodes, Electrode Caps and Holders

Electrode Materials

Figure 8.14

Figure 8.15
2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

112

Depending on the shape and type of electrode, solid electrodes or electrode caps, must be either remachined or recycled. Figure 8.14 depicts various types of electrodes, electrode caps and holders. Dependent upon the electrode application, different alloyed electrode materials are used, Figure 8.15. The added alloying elements influence the red hardness, the tempering resistance, the conductivity, the fusion temperature, the electrode alloying tendency, and, finally, the machinability of the electrode material. When beryllium is used as an alloying element, the admissible MAC values must be strictly adhered to during remachining or dressing of the electrodes. Already during the design phase of the components to be welded, importance must be attached to a good accessibility of the welding point. Moreover, the electrode force which is imperative to the process must be applied in a way that no damage is done to the workpiece. In the ideal case, the welding point is accessible from the top and from below, Figure 8.16.
poor good

poor

good

br-er8-16e.cdr

ISF 2002

br-er8-17e.cdr

ISF 2002

Accessibility for Spot Welding Electrode

Contact Area for Spot Welding Electrodes

Figure 8.16

Figure 8.17

2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

113

In order to avoid the displacement of the electrodes, the electrode working surface must be flat. Also during the design phase space must be provided for an adequately large
spot welding
A

clearing zone around the working point, in order to guarantee the unimpeded electrode approach to the working point, Figure 8.17.

shunt connection current

Dependent on the joining job, the process

current path copper

indirect welding one side

variation, or the resistance welding method, a so-called shunt current/effect may be noticed. This current component, as a rule, does not contribute to the formation of the weld nugget; under certain circumstances it might

roller seam welding

br-er8-18e.cdr

even prevent a reliable welding process. In the example, shown in Figure 8.18, the shunt

Shunting

Figure 8.18 current leads to undesired fusing contacts and, because of the lacking electrode force at this point, also to damages to the plate surface. If unsuitable welding parameters have been set, weld spatter formation may occur, Figure 8.19. Liquid molten metal forms on the plate surface or in the joining zone. The reasons for this kind of process disturbance are, for example, too low an electrode force with regard to the set welding current or welding time, too high an energy input with regard to the plate thickness or too small an edge distance of the welding point. Figure 8.19
2005
porosity in the joint caused by welding spatter
br-er8-19e.cdr

Welding spatter: Discharge of molten material between two steel sheets or from the surface of steel sheets.

fig. 1
Reason here is high welding current, (fig. 1) or too-small edge distance (fig. 2)

fig. 2

discharge of molten material at the joint plane

Welding Spatter

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

114

Figure 8.20 shows a list of

welding current changes
shunt connection wear of electrodes wear of cable mains voltage fluctuation secondary electrical impedance

a large number of possible disturbances in resistance spot welding. Welding curwear

alteration to force

alteration of pressure

Qeff = Qinput - Qlosses

Qeff

welding equipment

rent changes are caused by: shunt, electrode wear, cable wear, mains voltage variations, secondary impedance. Different welding conditions are caused by weld-

plate

diversion heat

plate thickness

quality of plates

number of plates

plate surface

edge distance

modification of the unit

br-er8-20e.cdr

Figure 8.20

ing machine wear, different heat dissipation. Non-

uniform conditions by alterations to components are: different plate thicknesses, plate quality, number of plates, plate surfaces, edge distances. Electrode force changes are caused by: pressure fluctuations and -changes, plate bouncing. The resistance spot welding method allows welding of a large number of materials. A list of the various materials is shown in Figure 8.21. The alloying elements which are used for steels have a varying influence on the suitability for resistance spot welding. The values which are indicated in the table are valid only when the stated element is the sole alloying constituent of the steel material. Figure 8.22 shows a comparison between resistance spot and resistance projection welding. The fundamental difference between the two methods lies in the definition of the current transition point. Figure 8.21
2005
weldable materials
br-er8-21e.cdr

materials

weldability
satisfactory

alloying elements

good weldability

sufficient weldability

aluminium iron gold cobalt copper magnesium

maximum content [%] very good satisfactory very good poor good C C + Cr C + Mo C+V C + Mn C + Ni Si Cu P+S C+Cr+Mo+V tantalum titanium tungsten very good very good satisfactory molybdenum satisfactory nickel platinum silver very good very good very good 0,25 0,35 0,50 0,40 1,40 3,00 0,40 0,60 0,10 0,60 0,40 1,60 0,70 0,60 1,60 4,00 1,00 0,60 0,10 1,60

influence of alloying elements (steel materials)

Weldable Materials

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

115

The differences between both methods are illustrated in Figure 8.23. The short life of the electrodes used for resistance spot welding is explained by the higher thermal load and the larger pressing area caused by the smaller electrode contact areas. The term electrode life stands for the number of welds that can be carried out with one pair of electrodes without further rework and without exceeding the tolerances for quality criteria of the weld. Depending on the defollow-up distance

before welding

after welding

mands on the joint strength or on the projection rigidity, different projection shapes are applied. These are anbr-er8-22e.cdr

elektrode

projection

nular, circular or longitudinal projections. The welding projections are, accordFigure 8.22

spot welding
elektrodes: diameter tip face electrode life up to 20 mm convex less

projection welding

embossed projection shape

solid projection shape

struck machined cut pushed

natural projection shape

> 20 mm flat longer

pressed mould pressed

place where the nugget originates

elektrodes

projections

circular longitudinal annular

circular longitudinal annular interrupted annular

spot contact line contact

number of welding nuggets

one

several

Circular

follow-up distance

small

big

weld nut

crossed wires

problems: current distribution force distribution no no yes yes

Longitudinal

cut

wire-plate

Annular
br-er8-23e.cdr ISF 2002
br-er8-24e.cdr

pushed

bolt-pipe

Differences Between Resistance Spot and Projection Welding

Customary Projection Shapes

Figure 8.23

Figure 8.24
2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

116

ing to their size, adapted to the used plate thickness and may, therefore, appear as difdie plate plate die

ferent types in the workpiece: embossed projections, solid projections and natural projections. The survey is shown in Figure 8.24.

d1
mould plate

mould plate counter-die

d1

In Figure 8.25 the production of embossed projections in different shapes is shown. The shape is embossed onto the plate surface by appropriate die plates, dies and, if necessary,

embossed projection

ring projection

die

l
mould plate

b
plate

counter dies. Various problems occur in projection welding caused by the welding of several joints in a single working cycle. Due to different current
ISF 2002

longitudinal projection
br-er8-25e.cdr

paths - when using direct current - and a current displacement - when using alternating current -, welding nuggets with differing quali-

Production of Embossed Projection Shapes

Figure 8.25

alternating current distribution intensity of current increases from the center to the outer area caused by current displacement

force distribution of a C-frame projection press welder during bending of machine tool frame

direct current distribution intensity of current decreases from the center to the outer area caused by the longer current path
br-er8-26e.cdr ISF 2002 br-er8-27e.cdr

force distribution of a C-frame projection press welder with non-parallel positioning tables
ISF 2002

Problem of Current Distribution During Projection Welding

Problems of Force Distribution During Projection Welding

Figure 8.26

Figure 8.27
2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding ties are produced when no preventive remedies are taken, Figure 8.26.

117

A varying force distribution, as shown by the example in Figure 8.27, also leads to differing qualities of the produced weld nuggets. In Figure 8.28 several examples of application using projection welding are debr-er8-30e_sw.cdr ISF 2002

picted. In this example, the shapes are of the embossed type.

Application Examples of Projection Welding

Figure 8.28 Figures 8.29 and 8.30 show several process variations of roller seam welding. Seam welding is actually a continuous spot welding process, but with the application of roller electrodes. In contrast to resistance spot welding the electrodes remain in contact and turn continuously after the first weld spot has been produced. At the points where a welding spot is to be produced again current flow is
lap joint lap joint with wire electrode lap joint with foil squash seam weld butt weld with foil

initiated. Dependent on the electrode feed rate and on the welding current frequency, spot welds or seal welds weld with nuggets overlapping are pro-

before welding

duced. The application of

after welding

d.c. current also produces seal welds.

br-er8-28e.cdr ISF 2002

Roller Seam Welding

Figure 8.29

2005

8. Resistance Spot-, Resistance Projection- and Resistance Seam Welding

118

interrupted-current roller seam weld

overlap seal weld

continuous D.C. seal weld

br-er8-29e.cdr ISF 2002

Weld Types for Roller Seam Welding

Figure 8.30

2005