REGIONAL INSTITUTE OF SCIENCE AND TECHNOLOGY
Topic:- RESISTANCE WELDING
Presented by:-
1. Syed Ashik Ahmed (19RISTEE001)
2. Abigail Iarisa Ryntathiang(20RISTLEE001)
3. Ariya Debbarma. (20RISTLEE002)
4. Benjaben Jamatia (20RISTLEE003)
Date:-
15/11/2022
Content:-
Introduction
Working principles
Types of resistance Welding
Advantages and Disadvantages
Application
Resistance Welding :-
Resistance welding, sometimes called
electric resistance welding (ERW),is a
process by which metals can be joined
together by applying pressure and
conducting a strong electric current
through the metal combination to heat up
the welding joint and melt the metals,
forging them together.
Working of Resistance Welding :-
Resistance welding is generally used to join two plain
metal work pieces together. An electric current is
delivered to the metal sheets (or any work pieces being
joined) through weld electrodes which apply force to the
sheets. This force is then converted to heat. The heat is
generated so that it melts the metal at the point where
they join – the point of ‘resistance’ between the faying
surfaces. The electrode then extracts heat from the
molten weld area which forms a weld nugget at the point
where it solidifies. A force is applied before, during and
after a current is applied, which confines the contact
area.
Types of Resistance Welding:-
There are many resistance welding processes with
different uses:-
spot welding,
seam welding,
butt welding,
projection welding,
Percussion welding .
1. Resistance Butt Welding:-
Resistance butt welding is a process in which the two components
of similar cross section can be joined together in one operation
that takes place simultaneously across the entirety of the
affected object, rather than just in small spots. The welding
application of butt welding is often in wires and rods with small
diameter measurements, generally up to about 16mm diameter.
2. Resistance Spot Welding:-
Resistance spot welding has been used extensively in the automotive
industry for the joining of steel and in the aerospace industry for airframe
components made from aluminium alloys. It is one of the oldest and
simplest forms of resistance welding, in which a weld nugget is produced
by passing an electric current between the two metal components whilst
they are held together between electrodes, typically made from copper-
based alloys due to its superior conductive properties.
3. Resistance Projection Welding :-
Resistance projection welding is a form of resistance welding where the
electricity, force, and weld time are concentrated on raised ‘projections’
across the surface. Projection welding is generally used for welds using
thicker materials than the thinner metal pieces that spot welding is
usually required for, and often not metals. It is used primarily in the
electrical, automotive and construction industries.
4. Resistance Seam Welding :-
Resistance seam welding is a variation of the standard spot welding form,
however instead of spot one nugget, a series of overlapping nuggets is
produced. This is usually done by replacing the conventional spot welding
electrodes with wheels, which turn as the parts are fed between them. The
process thus produces a continuous welded seam rather than a single spot.
Seam welding is often used in the production of thin sheet, leak-tight
containers such as fuel tanks, and is generally unsuitable for welding
aluminium.
5. Resistance percussion welding :-
It is one type of resistance butt-welding process. The parts to be welded are clamped in copper
jaws of the welding machine in which one clamp is fixed and other one is movable. The movable
clamp is backed up against the pressure from a heavy spring. The jaws act as
electrodes. Heavy electric current is connected to the workpieces. Now, the movable clamp is
released rapidly and it moves forward at high velocity. When the two parts are approximately 1.6
mm apart, a sudden discharge of electrical energy is released thereby causing an intense arc
between two surfaces. The arc is extinguished by the percussion blow of the two parts coming
together with sufficient force to complete in 0.1 second. No upset or flash occurs at the weld. This
method is primarily employed to join dissimilar metals. This method is limited to small areas of
about 150 to 300 mm2.
Welding energy, E = ½ CV2
where
E = energy in watt-seconds (Joules)
C = capacitance in farads
V = voltage
Resistance welding of advantages and disadvantage :-
Advantages:-
1: This method is simple and does not necessary high expert labor.
2: The resistance welding metal thickness is 20mm, & thinness is 0.1 mm
3: Automated simply
4: The rate of production is high
5: Both related, & different metals can be weld.
6: Welding speed will be high
7: It does not need any flux, filler metal & protecting gases.
Disadvantages:-
1: Tools cost will be high.
2: The work section thickness is limited because of the current requirement.
3: It is less proficient for high-conductive equipment.
4: It consumes high electric-power.
5: Weld joints contain small tensile & fatigue power.
Resistance Welding Application:-
This type of welding can be widely used within
automotive industries, making of nut as well as a
bolt.
Seam welding can be utilized to generate leak prove
joint necessary within little tanks, boilers, etc.
Flash welding can be used for welding tubes and
pipes.
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