Table of Contents

1 Title..........................................................................................................................................1
2 Objectives.................................................................................................................................1
3 Welding....................................................................................................................................1
3.1 Example............................................................................................................................1
4 Spot welding.............................................................................................................................1
4.1 Explanation.......................................................................................................................1
4.2 Estimation of energy.........................................................................................................2
5 Equipment................................................................................................................................2
5.1 Tool holders......................................................................................................................2
5.2 Electrodes..........................................................................................................................2
6 Mechanism of Spot Welding....................................................................................................3
7 Parameters of spot welding......................................................................................................3
7.1 Electrode force..................................................................................................................3
7.2 Diameter of electrode contact surface...............................................................................3
7.3 Squeeze time.....................................................................................................................3
7.4 Weld time..........................................................................................................................4
7.5 Hold time...........................................................................................................................4
7.6 Weld current......................................................................................................................4
8 Metals welded by resistance welding.......................................................................................4
9 Advantages of Resistance Welding..........................................................................................5
10 Disadvantages of Resistance Welding..................................................................................6
11 Applications..........................................................................................................................6
12 Conclusion............................................................................................................................6
1 Title
To learn about spot welding process

2 Objectives
 To understand basics of resistance welding process
 To understand heat generation and control

3 Welding
 It is a fabrication process in which two or more parts are fused together with the help of
heat, pressure or both forming a join as parts cool.
 Welding is usually used on metals and thermoplastics but now can also be used on wood.
 The joint part of welding is known as weldment.
3.1 Example
Joining of two parts of cycle is welding.

4 Spot welding
 It is a type of electrical resistance welding.
 It is used to weld various metal sheets products
 In which metal surface points are joined by the heat obtained from resistance to electric
current.

Fig 01: Spot Welding

4.1 Explanation
 This process uses two shaped copper alloy electrodes to concentrate welding current into
a small spot.
 It can clamp the sheet together with more grip.

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  Work piece are held under normal pressure exerted by electrodes. The thickness range of
sheet is 0.5 to 3 mm or 0.20 to 0.118 in. The attractive feature of spot welding is that
spots get more energy in a very short of time (approx. 10 to 100 milliseconds).

Fig 02: Spot Welding Overview

4.2 Estimation of energy

 The amount of heat is determined by the resistance between thew electrodes, the
magnitude and duration of metal that is delivered to the spot.
 The amount of energy we given to spot because to match the sheet’s material, thickness
and type of electrode.
 Applying very high energy to spot for melting the metal for welding otherwise low
energy will be the result of poor welding.

5 Equipment
There are two equipment used in spot welding.
 Tool holders
 Electrodes

5.1 Tool holders

 The function of tool holder is to hold the electrodes firmly in place.
 It includes a paddle type, light duty, universal and regular offset.

Fig 03: Tool holders

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5.2 Electrodes
 It is generally made up of low resistance alloy, usually copper.
 It is designed in many different shapes and sizes depending on the application needed.
Fig 04: Electrodes

6 Mechanism of Spot Welding

 Electrodes are brought in contact to surface of metal where we want to weld and applying
slight amount of pressure.
 The current is applied shortly and after short time current is removed.
 But the electrodes remain in place for the material to cool down.
 Weld time range from 0.001 sec to 0.63 seconds depending on the thickness of metal.

7 Parameters of spot welding

There are following parameters of spot welding that are given below.
 Electrode force
 Diameter of electrode contact surface
 Squeeze time
 Weld time
 Hold time
 Weld current

7.1 Electrode force

It is a force that is present between electrodes during the welding process. This force directly
effects on resistance between electrodes.

7.2 Diameter of electrode contact surface

Diameter of electrode surface is ranging from 0.25 mm to 25 mm and height of electrode is 0.5
mm to 3.8 mm.

7.3 Squeeze time

It is the time interval between initial application of the electrodes and the first application of
current. It is the time when pressure is control.

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7.4 Weld time
It is a time during which electric current is applied to the metal sheet for welding process. The
approximately time of welding is 0.001 to 0.63 seconds depending on the condition of metal
sheet.

7.5 Hold time

It is a time to cool down the welding sheet after applying the welding process.

7.6 Weld current

The amount of current pass through the spot to create spot welding process.

8 Metals welded by resistance welding

The following metals are mostly welded by resistance welding

 Low carbon steel

Fig 05: Low carbon Steel

 Aluminium alloys

Fig 07: Aluminium alloys

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  Medium carbon steels

Fig 08: Medium carbon steel

 High carbon steels

Fig 09: High carbon steel

 Alloy steel

Fig 10: Alloy steel

9 Advantages of Resistance Welding

It could be
 High welding rates
 Low fumes
 Cost effectiveness
 Easy automation

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  Low distortions
 No filler materials are required

10 Disadvantages of Resistance Welding

It has
 High equipment cost
 Low strength of discontinuous welds
 Welded sheets that has thickness range is limited to 1/4@” (6 mm).

11 Applications
Resistance welding is used for
 Joining vehicles body parts.
 Fuel tanks.
 Domestic radiators.
 Pipes of gas oil.
 Water pipelines.
 Wire ends.
 Turbine blades.
 Railway tracks.

12 Conclusion
In comparison with other welding processes, RSW is fast and easy for automation. This process
involves electrical, thermal and mechanical interactions.

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