PRESENTATION

RESISTANCE WELDING

GROUP 5
Chandra Dini

(02810)
Ilham Romadhona
(02858)
Ferry Andriawan
(03842)
Veronika Nurdiana (05383)

What is welding???
Welding is the process of joining two pieces of
metals by heat the parts, with or without
pressure until melting, and then freeze and two
metals joining.

RESISTANCE WELDING
Resistance Welding is a welding process, in which work
pieces are welded due to a combination of a pressure applied
to them and a localized heat generated by a high electric
current flowing through the contact area of the weld.

The following metals may be

welded by Resistance Welding
Low carbon steels - the widest application of

Resistance Welding
Aluminum alloys
Medium carbon steels,high carbon
steelsandAlloy steels(may be welded, but
the weld is brittle)

Advantages of Resistance
Welding:
High welding rates;
Low fumes;
Cost effectiveness;
Easy automation;
No filler materials are required;
Low distortions.

Disadvantages of Resistance
Welding:
High equipment cost;
Lowstrengthof discontinuous welds;
Thickness of welded sheets is limited - up to

1/4 (6 mm);

The most popular methods

of Resistance Welding are:
Resistan
ce
Welding
Spot
Welding
(RSW)

Seam
Welding
(RSEW)

Resistance
Butt
Welding
(UW)

Flash
Welding
(FW)

Percussion
Welding

Projection
Welding

HFRW

Spot Welding
Spot Weldingis aResistance
Weldingprocess, in which two or more
overlapped metal sheets are joined by spot
welds.
The method uses pointed copper
electrodes providing passage of electric
current. The electrodes also transmitt
pressure required for formation of strong
weld.
Diameter of the weld spot is in the range
1/8 - 1/2 (3 - 12 mm).

Spot welding is widely used in automotive industry for

joining vehicle body parts.

Single and Multiple Spot

Welding
Single spot welding

Multiple Spot
Welding

Seam Welding
Seam
Weldingis
aResistance
Weldingprocess of continuous joining of
overlapping sheets by passing them between
two rotating electrode wheels. Heat generated
by the electric current flowing through the
contact area and pressure provided by the
wheels are sufficient to produce a leak-tight
weld.

Seam Welding is high speed and clean

process, which is used when continuous tight
weld is required (fuel tanks, drums, domestic
radiators).

Flash Welding
Flash
Weldingis
aResistance
Weldingprocess, in which ends of rods (tubes,
sheets) are heated and fused by anarcstruck
between them and thenforged(brought into a
contact under a pressure) producing a weld.
The welded parts are held in electrode clamps,
one of which is stationary and the second is
movable.

Thick pipes, ends of band saws, frames, aircraft landing gears are
produced by Flash Welding.

Resistance Butt Welding

Resistance Butt Welding is a Resistance Welding
process, in which ends of wires or rods are held under a
pressure and heated by an electric current passing through
the contact area and producing a weld.

The process is similar toFlash Welding, however in Butt

Welding pressure and electric current are applied
simultaneously in contrast to Flash Welding where electric
current is followed by forging pressure application.

Butt welding is used for welding small parts.

The process is highly productive and clean. In
contrast to Flash Welding, Butt Welding
provides joining with no loss of the welded
materials.

Percussion Welding
Percussion or Percussive welding is similar to
flash welding except that the arc is produced by
the rapid discharge of stored electrical energy
across an air gap between the ends of the work
pieces to be welded.

Principle of Operation

Applications of Percussion Welding:

1. Welding of satellite tips to tools
2. Welding of Steel to Cast Iron
3. Welding of Zinc to Steel
4. Welding of Copper to Aluminium
5. Welding of Studs
6. Join a stranded wire directly to a component pin on axis

Projection Welding
Projection Welding (RPW) is a resistance
welding process which produces coalescence of
metals with the heat obtained from resistance
to electrical current through the work parts held
together under pressure by electrodes.

The resulting welds are localized at predetermined

points
by
projections,
embossments,
or
intersections. Localization of heating is obtained
by a projection or embossment on one or both of
the parts being welded.

The Advantage
The Advantage of projection welding is that
electrode life is increased because larger
contact surfaces are used. A very common use
of projection welding is the use of special nuts
that have projections on the portion of the part
to be welded to the assembly.

High Frequency Resistance Welding

High frequency resistance welding

(HFRW)is a resistance welding process which
produces coalescence of metals with the heat
generated from the resistance of the work
pieces to a high-frequency alternating current in
the 10,000 to 500,000 hertz range and the
rapid application of an upsetting force after

This process is ideally suited for making pipe,

tubing, and structural shapes. It is used for
other
manufactured
items
made
from
continuous strips of material.

Thank You