PLASTIC AND RESISTANCE WELDING

THEORY OF RESISTANCE WELDING

1. In resistance welding both heat and pressure are used to induce
coalescence.
2. Electrodes are placed in contact with the material, and electrical
resistance heating is used to raise the temperature of the work-
pieces and the interface between them.
3. The same electrodes that supply the current also apply the
pressure, which varies during the welding process.
4. A certain amount of pressure is applied initially to hold the wok-
pieces in contact, and thereby control the electrical resistance at
the interface.
5. When proper heating has been attained, the pressure is increased
to obtain coalescence.
6. Since pressure is applied, coalescence occurs at a lower
temperature than that required for oxyfuel or arc welding.
7. The required temperature and coalescence can be achieved in a
few seconds.
 HEATING
1. The heating is obtained by passing a large electric current
through the work-pieces for a short period of time.

2. The amount of heat input can be determined by the basic

relationship:
H = I2 R t
where: H = total heat input in joules
I = current in amperes
R = electrical resistance of the circuit in ohms
t = length of time during which current is
flowing in seconds.
 THE ELECTRIC CIRCUIT

1. The work-pieces actually form

part of the electric circuit.
2. The total resistance between
the electrodes consist of three
distinct components:
a. The bulk resistance of the
electrodes and workpieces—the
upper electrode, upper
workpiece, lower workpiece,
and lower electrode.
b. The contact resistance between the
electrodes and the workpieces—between the
upper electrode and upper workpiece and the
lower electrode and lower workpiece.
c. The resistance between the surfaces to be
joined, known as the faying surfaces.
• Therefore, it is essential to keep components “a” and “b” as low as
possible with respect to resistance “c”. The bulk resistance of the
electrodes is always quite low, and that of the work pieces is determined
by the type and thickness of the metal being joined. Because of the large
areas involved and the relatively high electrical conductivity of most
metals, the work piece resistances are usually much less than the contact
or interface values.
• Resistance “b” (the resistance between the electrodes and workpieces)
can be minimized by using electrode materials that are excellent electrical
conductors and by controlling the size and shape of the electrodes and the
applied pressure. Any change in the pressure between the electrodes and
workpieces, however, also affects the contact between the faying surfaces.
Therefore, the ability to control the electrode-to-work resistance by
pressure variation is quite limited.
• The final resistance, that between the faying
surfaces, is a function of (1) the quality
(surface finish or roughness) of the surfaces;
(2) the presence of nonconductive scale, dirt,
or other contaminants; (3) the pressure; and
(4) the contact area. These factors must all be
controlled if uniform resistance welds are to
be produced.
 HEATING FUNCTION
1. It is desirable to have the max temperature
occur where the weld is to be made.
2. Resistance of the faying surfaces is kept
higher than the material other two
resistances.
3. Work-piece resistance depends on
thickness and type of metal.
4. Resistance between work-piece and
electrode is kept low by using good
conductor material electrodes.
5. Resistance between faying surfaces is a
function of surface finish of surfaces,
presence of non-conducting scale, dirt or
other contaminants.
 FORMATION OF WELD NUGGET

Top Electrode
Water
Weld
Nugget

Distance

Resistance
Bottom Electrode
 PRESSURE FUNCTION
1. Pressure promotes a forging action, therefore resistance welds can
be produced at lower temperatures than welds made by other
processes.
2. Control of magnitude and timing of pressure is very important.
3. If too little pressure, contact resistance will be high, surface
burning or pitting of the electrodes may occur.
4. If excessive pressure, molten or softened metal may be expelled
from between faying surfaces, or indented by the electrodes.
5. Ideally, moderate pressure should be applied to hold the work-
pieces in place and establish proper resistance at the interface
before passage of the current.
6. The pressure should then be increased considerably just as the
proper welding heat is attained.
7. On large production type welders, pressure is applied through
controllable air or hydraulic cylinders.
 CURRENT FUNCTION
1. With the surface conditions held constant, and the pressure
controlled, the temperature in resistance welding is
regulated by controlling the magnitude and duration of the
welding current.

2. Very precise and sophisticated controls are available for this

purpose.

3. In large production type welders, the magnitude, duration

and timing of both current and pressure can be programmed
to follow specified cycles.

4. Since the resistance of welding circuits can be very low, high

currents are generally required to welding.
TYPICAL EQUIPMENT OF RESISTANCE SPOT WELDING

(a) (b)
[Reference: Welding Process Slides, The Welding Institute]
PROCESS OPERATION OF RESISTANCE SPOT
WELDING

[Reference: Welding Process Slides, The Welding Institute]

 TYPES OF RESISTANCE WELDING
SPOT RESISTANCE WELDING:
1. Is the simplest and most widely used form of resistance welding.
2. Overlapping sheets are placed between water cooled electrodes.
3. Electrodes have reduced area at the tips to produce welds of 1/16 to ½
inch diameter.
4. The electrodes close on the work, and the controlled cycle of pressure
and current is applied to produce a weld at the metal interface.
5. The electrodes then open, and the work-piece is removed.

RESISTANCE SEAM WELDING:

6. The seam is usually a series of overlapping spot welds.
7. The basic equipment is the same as for spot welding, except that the
electrodes are in the form of rotating discs.
8. As the metal passes between the electrodes, timed pulses of current pass
through it to form the overlapping welds.
 TYPES OF RESISTANCE WELDING
BUTT WELDS:
1. A continuous seam is produced.
2. Makes butt weld between thicker plates.
3. Electrical resistance of abutting material is used to generate heat.
4. High frequency current is used to restrict the heating only to the
immediate surrounding of the joint.
5. When they attain the required temperature, the heated surfaces are
pressed together to form the weld.
 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]
 ADVANTAGES OF RESISTANCE WELDING
1. Adaptability for Automation in High-Rate
Production of Sheet Metal Assemblies

2. High Speed/ very rapid

3. Economical. No filler metal, or flus is requird.

4. Dimensional Accuracy

5. Skilled operators not required

6. Dissimilar metals can be easily joined

 LIMITATIONS OF RESISTANCE WELDING

1. Difficulty for maintenance or repair. Skilled people

required.
2. There are limitations to the type of joints that can be
made
3. Generally have higher cost than most arc welding
equipment
4. For some materials, the surfaces must receive special
preparation prior to welding.
End of lecture