Resistance welding is a common fabrication process that allows manufacturers to quickly create a strong bond between two or more metal components. This versatile process generates reliable and precise welded joints while reducing the risk of distortion and improving operational productivity. To determine if resistance welding is right for your project, read on to learn about this welding technology and how it is beneficial to production.
Resistance Welding Process
Resistance welding joins metal sheets or parts together using force and the heat resulting from welding current flow resistance. By applying precise pressure to a workpiece throughout the welding process, resistance welding equipment passes an electric current for a predetermined amount of time through electrodes acting as conductors. These electrodes administer the force and focus the current at precise points on a workpiece, melting the metal at those localized points to form a bond between parts and create a welded joint. Often made of copper alloys for their excellent conductivity, the electrodes cool as water passes through their internal cavities and other resistance welding machine tooling.
Resistance welding encompasses several methods, including spot and projection welding, that use electrodes of dissimilar shapes or types as current conductors. Among the oldest welding techniques yet still applicable today, spot welding bonds metal using a combination of pressure and heat applied by an electrical current. The melted metal generates a weld pool that, as it cools, attaches the separate metal components to one another. Projection welding also relies on force, heat, and electrical current to form a weld joint. In this case, however, the component being welded usually has projections like on a weld nut that, as part of their design, are intended to melt and collapse, forming a strong weld nugget.
Benefits of Resistance Welding
Regardless of the type, resistance welding offers many advantages over other welding techniques. Resistance welding provides:
- Speed. The welding process time is short for resistance welding, enabling rapid production. Additionally, resistance welding is an easy process to automate for achieving higher productivity without sacrificing quality.
- Increased efficiency and output. Due to the above capabilities, resistance welding is suitable for quickly producing a high volume of products efficiently. This allows for improved production, increased profits, and reduced turn times.
- Precision. Resistance welding forms joints electro-mechanically for high reliability. The work area is small and localized, causing minimal heat-related distortion to the workpiece for a better finish. Also, joints made using this technique are highly replicable.
- Versatility. This method is capable of welding workpieces with differing metal compositions and thicknesses.
- Affordability. The resistance welding process is a cost-effective one. Beyond an adequate supply of electricity and small electrode wear, it does not rely on other consumables like welding rods, solder rods, or brazing materials. Filler metals are unnecessary, as well.
- Environmental friendliness. Resistance welding is an environmentally friendly and clean welding option. Using electric current and pressure to create welded joints means that the process does not require shielding gasses or consumable metal materials.
Resistance Welding From Clairon Metals
At Clairon Metals Corporation, we have over three decades of experience fabricating metal parts for industries ranging from automotive and trucking to HVAC and solar. We offer an array of on-site resistance welding services, including spot welding and projection welding, utilizing 15 programmable and automated resistance welding cells for rapid production while yielding quality results in thin- or heavy-gauge steel.
Our resistance welding services and extensive knowledge base in various other types of welding allow us to provide solutions for most welding applications. The Clairon Metals team will work closely with you to find a suitable welding method that best meets your project’s requirements. We will design and fabricate weld fixtures and then inspect those fixtures to ensure accurate replication, all with a focus on superior customer service.