Spot Welding

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 or Welding Tips Electrodes or Welding Wheels Electrodes or Dies

Projection Welds

Spot Weld

Seam Weld
Electrodes or Dies

Projection Weld

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 I = Current (Amps) R = Resistance (Ohms) T = Time (Cycles 1/60 Second) K = Heat Losses Is a function of: Transformer Tap Setting Material Prop., & Pressure Control Setting Conduction, Convection, Radiation

Heating Value of Current = RMS Current Irms=0.707 Ipeak

Block Diagram of Single-Phase Spot Welder

Contactor

Main Power Line

Spot Weld

N=np/ns Vs= Vp/N Is = Ip N

Heat = I2 RTK Where I = Current (Amps) R = Resistance (Ohms) T = Time (Cycles 1/60 Second) K = Heat Losses Is a function of: Transformer Tap Setting Material Prop., & Pressure Control Setting Conduction, Convection, Radiation

Contact-Resistance Measurement
Electrode Rec Force

Small Current Rec Rsc Rv Rv

Rec = contact resistance between electrode and sheet surface

Rsc = contact resistance at the faying surface Rv = volume resistance of the sheets

Rtotal

Rec

Contact Area
Rec Electrode Force

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.

(a) Pickled Conditions

Surface Condition
Steel

(b) Rusted Conditions Oils/Dirt Oxide

Resistivity

Steel

Steel

Rusty
Polished Pickled

Oxide Oils/Dirt Steel

Electrode Force

Resistance Varies with Pressure

Low Pressure

Medium Pressure

High Pressure

(a)

(b)

(c)

Volume-Resistance Measurement
Electrode Force

Small Current Rec Rsc Rtotal Rec Rv Rv

Rec = contact resistance between electrode and sheet surface

Rsc = contact resistance at the faying surface Rv = volume resistance of the sheets

Contact Area
Rv Electrode Force

Resistivity as a Function of Temperature

130 120 110 100 90 80 70 60 50 40 30 20 10

Resistivity, mW-cm

HSLA

Low Carbon

100 200 300 400 500 600 700 800

Temperature, C
[Reference: Welding in the Automotive Industry, D.W. Dickinson, p.125]

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 during welding.

Workpiece

Electrode

At the end of welding time

After 20% welding time

Temperature