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Resistance welding is welding parts to be pressed between two electrodes, and through the current use of current flowing through the workpiece and the contact resistance of heat generated by adjacent areas will be heated to melt or its plastic state, so as to form metal-binding methods.

Types of Resistance Welding

There are two main types of resistance welding: 1) Resistance Spot Welding 2) Resistance Seam Welding

1) Resistance Spot Welding

Resistance spot welding is by far the predominant process in this group. It is widely used in mass production of automobiles, appliances, metal furniture, and other products made of sheet metal. If one considers that a typical car body has approximately 10,000 individual spot welds, and that the annual production of automobiles throughout the world is measured in tens of millions of units, the economic importance of resistance spot welding can be appreciated.

Advantages of Resistance Spot Welding

Process is simple The heating time is short Do not need to wire, welding filler metal, etc Simple, easy to mechanization and automation, improved working conditions. The production rate, and no noise and harmful gases Spot welding can be performed without any special skill Spot welding can be used to join many different metals, and can join different types to each other

Disadvantages of Resistance Spot Welding

There is a lack of reliable non-destructive testing methods Higher equipment costs than arc welding Power line demands Low tensile and fatigue strength Not portable Electrode wear

2) Resistance Seam Welding

In resistance seam welding (RSEW), the stick-shaped electrodes in spot welding are replaced by rotating wheels, as shown in figure and a series of overlapping spotwelds aremade along the lap joint.The process is capable of producing air-tight joints, and its industrial applications include the production of gasoline tanks, automobile mufflers, and various other fabricated sheet metal containers.

Advantages of Resistance Seam Welding

High speed, from 1 to 10 m/min Easily automated Suitable for high production rate

Disadvantages of Resistance Seam Welding

High initial equipment costs Difficulty of access to the component Limited by the components geometry

Applications of Resistance Seam Welding

Domestic radiators Vehicle fuel tanks Plastic bags

Oxyacetylene welding (OAW) is a fusion-welding process performed by a high-temperature flame from combustion of acetylene and oxygen. The flame is directed by a welding torch. A filler metal is sometimes added, and pressure is occasionally applied in OAW between the contacting part surfaces.

Advantages of OAW
High industrial applications It's easy to learn The equipment is cheaper than most other types of welding The equipment is more portable than most other types of welding OAW equipment can also be used to "flame-cut" large pieces of material The welder has considerable control over the temperature of the metal, filler-metal deposition rate Clearly view the weld area. Heat can be applied preferentially to the base metal or the filler metal without removing either from the flame envelope No need to electricity. Thin metals with poor fit-up can be welded Small diameter pipes can be welded

Disadvantages of OAW
A wide heat affected zone Slow process Gases are expensive Work-piece thickness is limited up to 6 mm OAW require more finishing if neatness is required. OAW is a manual process thus a very skilled welder is required for the process