Resistance Welding

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 Resistance welding is a type of welding process that joins metals by applying pressure and electrical resistance-generated heat to melt and fuse the materials together. This method is commonly used for joining sheet metals in various industries. There are several different types of resistance welding processes, each with its specific characteristics and applications. Here are some of the main types:

1. Spot Welding:
In spot welding, two electrode points are pressed against the metal sheets to be joined. A high current is then passed through the workpieces at the spot where the electrodes touch, creating resistance heating that melts and fuses the metals together. This process is used in the automotive industry to join sheet metal parts in vehicle body construction.
2. Projection Welding:
Projection welding is similar to spot welding but is typically used to weld parts with raised weld points or projections. The raised sections concentrate the heat and pressure, allowing for precise welding in designated spots. It's used in applications such as welding nuts onto metal parts or attaching fasteners.
3. Seam Welding:
Seam welding is used to create continuous welds along the length of a seam. It's commonly used in the production of tubes, pipes, and containers. The workpieces are continuously fed between rotating electrode wheels, which create a continuous weld seam.
4. Flash Butt Welding:
Flash butt welding is a process where the ends of two metal pieces are clamped together and subjected to an electrical current. The resistance heating creates a flash, which is the excess material that's removed during the process, leaving a clean welded joint. It's used in applications such as rail welding.
5. Upset Welding:
Upset welding is used to join the ends of two rods or wires by applying pressure and heat. The ends of the workpieces are upset (enlarged) before they're joined together. It's commonly used for joining wires in the construction of wire mesh and fencing.
6. High-Frequency Resistance Welding:
High-frequency resistance welding is often used for joining thin-walled metal tubes and pipes. It utilizes high-frequency current to generate heat quickly, allowing for efficient welding without causing distortion to the workpieces.

Resistance welding offers several advantages, including high production rates, minimal consumables (no filler material or gas required), and the ability to create strong, durable welds. However, it's primarily suitable for joining metals with good electrical conductivity, like steel and aluminum. The choice of the specific resistance welding process depends on the materials, the geometry of the workpieces, and the desired joint characteristics.



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