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Welding Spark

Resistance Welding

Resistance welding refers to the joining of two pieces of metal by applying pressure and heat to weld electrodes creating a welded joint.  

One of the main advantages of this type of welding is that no other materials are needed, which make this one of the most cost-effective welding methods.

Resistance welding is ideal for various applications, including:

  • Automotive
  • Aerospace
  • Industrial

What is A Resistance Welding Process?

Two pieces of metal to be joined are squeezed together by electrodes on the welding machine so they are in good electrical contact.

An electric current is passed through them, heating them until they begin to melt at the spot where they are in contact.

The molten metal from the two pieces flows together; then the current is turned off and the molten metal solidifies, forming a solid metallic connection between the two pieces.

The term “Resistance Welding” comes from the fact that it is the electrical property of resistance of the metal being welded that causes heat to be generated when current flows through it.

Types of Resistance Welding Applications

There are many different types of resistance welding.  Each differs depending on the type and shapes of the weld electrodes that are used to apply the pressure and conduct the current.

  1. Spot welding
  2. Projection welding

Spot Welding

This is the simplest type of resistance welding.  Two or more metal sheets are bonded together while being held in an overlapping position between a pair of welding electrodes: one fixed and one mobile.

When a current is directed through the electrodes, the top electrode simultaneously adds downward pressure.  This results in a weld that takes place between the two electrodes.

Further welds are created by repositioning the sheets.

Spot welding is ideal for various applications, including:

  • Automotive
  • Aircraft
  • Steel household furniture
  • Steel containers

Benefits of Spot Welding

  • More control and uniform welds
  • Low cost

Projection Welding

Projection welding is used primarily in:

  • Electrical
  • Automotive
  • Construction

This welding process also connects components parts using welding electrodes.

Electrodes are applied directly to the metal pieces.  Opposing forces are run through the electrodes. Typically, one of the components has one or more weld projections to direct the heat in a localized area.

Benefits of Projection Welding

  • Flexibility
  • Neater and less obtrusive welds
  • Welding locations can be positioned more closely

Advantages of Resistance Welding

  • Ability to weld .010”-.125 thick materials
  • High welding speed
  • Automated
  • Similar and dissimilar metals are capable of being welded
  • High production rate
  • Environment-friendly process
  • No need for filler metal, flux, and shielding gases

Resistance Welding Services at Norstan

At Norstan, we specialize in both spot welding and projection welding.  With our knowledgeable and responsive team, we can help you with your application.  Contact us about our resistance welding services today!

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