Spot welding how does it work

Spot welding has applications in a number of industries, including automotive , aerospace , rail , white goods, metal furniture, electronics , medical building and construction. Given the ease with which spot welding can be automated when combined with robots and manipulation systems, it is the most common joining process in high volume manufacturing lines and has in particular been the main joining process in the construction of steel cars for over years.

The electrodes are one of the most important factors in the resistance welding process but often the most abused Aluminium and its alloys have high thermal and electrical conductivity compared with steel and, as the process depends on In an effort to guarantee weld quality, weld parameter settings are often set close to a splash condition Surface splash and electrode sticking are a result of excessive heating between the electrode and the sheet material being joined Support for SMEs.

Software Products. Go to Technical knowledge Search. Login Login. Members' Portal. What is Spot Welding? A Complete Welding Process Guide. If you have any questions or need help, email us to get expert advice: contactus twi.

How Does Spot Welding Work? This is calculated in line voltage cycles. However, the weld time is difficult to accurately determine because it is dependent on what needs to be done for the weld spot. In other words, the best weld time for quality welding is one that is as short as possible. As the name implies, hold time refers to the duration after welding when the electrodes remain in contact with the sheet. This is done to allow the weld area to cool down.

The weld chunk then solidifies before the welded parts are released. If the hold time is stretched out, the heat in the weld spot may spread to the electrode and heat it, which will start to wear out. Additionally, if the material has high carbon content and the hold time is high, the weld may become brittle and develop cracks. However, if you remove the electrodes before the nugget becomes solid, it may pull apart, resulting in a weak weld.

Spot welding is a popular welding method in the automobile industry because it is a cheap but efficient way to merge sheet metal. As such, it can be utilized either with trained rudimentary staff or robots since it requires little skill. The bottom line is that the welding process is fast and effective, which means more cars developed per shift. This welding method is used liberally in manufacturing electronics such as circuit boards, gas sensors, and even solar panels.

This method is known as electronic resistance welding and is also used to create complex and delicate electrical components from cables to switches and hand tools. Most people are unaware of this, but spot welding is also used to join rolls of nails. Steel wires are welded to nails at high speeds by using pneumatic nail gun magazines. Of course, to ensure the nails are secured to the wires accurately, the current that is applied has to be precise as possible at the point where the point of the nail is under the welding wheel.

Is spot welding easy? Spot welding is among the earliest welding procedures and is very well-known and easy to do for even beginner welders.

The procedure is totally defined and readily applies to a lot of thin metals like stainless steel, nickel alloys and titanium. It is often utilized in aerospace and automotive businesses, but improvements are highly desired. How thick can you spot weld? Spot welding is largely employed for linking parts which are normally around 3 millimeters in thickness.

Thickness of those components to be welded ought to be equivalent or the proportion of thickness ought to be less than The strength of this joint is dependent upon the quantity and size of this welds. Spot-weld diameters range from 3 mm to Can you spot-weld aluminum? Spot welding aluminum is getting a lot more common as aluminum replaces steel in numerous applications where weight is important, like cars.

You can take advantage of three-phase electric power to spot-weld lightweight aluminum. Spot welding typically supplies current for 0. Additional menu. How spot welding works The best way to understand how spot welding works is to follow the steps that go into it. Here is a brief overview: Step 1 — workpieces and metallic sheets are aligned First, the workpieces or metal sheets are lined up precisely.

Welders are also always around hazardous fumes and sparks, which pose a significant risk to their health. Other risks posed to welders include crashing and injuring themselves, especially hands and fingers.

Spot welding is not suitable for welding thicker materials. The final weld will be of low quality since the spot weld will not penetrate appropriately. By this weakness, projects done using spot welding easily break apart, requiring you to do repairs regularly. Spot welding is primarily used to join thin materials with thicknesses of around 3 millimeters. When welding components with different sizes, ensure the ratio of thickness is not greater than The strength of the final weld will depend on the quantity and size of each material.

Your final product should have a spot-weld diameter ranging from 3 mm to Over the years, the welding industry has gradually shifted from using steel to the use of aluminum. This replacement has happened in numerous applications such as car manufacturing, where weight is a significant component. Most welders prefer taking advantage of the three-phase electric power to spot-weld and manufacture lightweight aluminum products. The high amount of electricity needed in such welding makes spot welding the most suitable method.

The turnaround time in which spot welding supplies electric current is 0. Resistance welding involves the resistance caused by the material to the flow of current. In this process, the final weld is formed by combining pressure, time, and heat. The welded parts are usually held down by the pressure exerted by the electrode tips and tongs.

Spot welding is best applied when you require small cross-section welds. Welders can also repeat the method as many times as they wish. They only need to check on the size of the workpiece. Cameron grew up in Allentown, Pennsylvania, a once-proud steel town on the Lehigh River, where he got a taste of TIG welding in his high school shop class.

His interests include scuba diving, sculpture, and kayaking. Water Welders is reader-supported. When you buy via links on our site, we may earn an affiliate commission at no cost to you. Learn more. Understanding it Thoroughly Last Updated on Sep 27 Spot welding, also known as electrical resistance welding, is ranked among the oldest forms of welding.

How Does Spot Welding Work? First, let us understand the steps used in the spot welding process. Here is an overview. Aligning of Workpieces and Metallic Sheets Before welding begins, all the workpieces and metallic sheets are lined up accordingly.

Pressing Electrodes The process of passing electrodes involves choosing suitable electrodes for welding your workpieces. Allowing Current to Flow through the Electrodes In this process, you are required to position your electrodes in their correct designated areas. Credit: Fusionstudio, Shutterstock.

In determining the welding time, here are the factors to consider:. Credit: Praphan Jampala, Shutterstock. Advantages of Using Spot Welding. The Method is Quick Spot welding is known to have a short turnaround time in yielding results. Easy to Understand Spot welding is among the oldest and well-known forms of welding.

Proven and Tested Spot welding has high compatibility with efficiency and uniformity. Energy Efficiency Welding using the electrical resistance method requires a minimal amount of energy and electricity. Disadvantages of Friction Welding. Requires a Large Working Area Spot welding cannot be done in a small or confined working space. Can be Dangerous The welding guns used in spot welding are heavy and require great strength when using them.

Spot Welding Can be Weak Spot welding is not suitable for welding thicker materials. The electrode tips and tongs also work as conductors through which electric current flows during the welding cycle. Several factors usually determine the welding duration. These factors include:.

Aligning of Workpieces and Metallic Sheets 2. Pressing Electrodes 3. The Force of the Electrodes 2.