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Resistance Welding
Q. What is the important condition for resistance welding?
Laser Welding
A. Resistance welding mainly depends on the following five conditions:
Resistance welding is to cause current to generate heat to weld; therefore, the magnitude of current, weld
time, and current density are important factors. Weld force is also important.
A. It depends on what is required. Tensile strength test and peel test measure weld strength and nugget size;
additionally, cross section is observed. Our Weld Checker is useful for quality control.
Q. Resistance welding usually forms molten material at welding points in order to join two metal sheets. What
does micro-resistance welding create at the faying surface?
A. A. Heat is generated by the welding current due to the intrinsic resistance and the contact resistance alone.
However, welding mechanisms are categorized into three types depending upon the materials of the
workpieces.
The joining of iron, iron alloy, or aluminum workpieces by the micro-resistance welding forms spots of
cooled molten material (nuggets) at the faying surface, as is the case with normal resistance welding. Thin
and flat nuggets are formed on both sides of the interfacing surface.
Copper sheets are bonded together immediately before melting, and are joined by diffusion. No nuggets are
observed under an optical microscope. This welding increases temperature until a molten state is formed.
[Welding of a 0.3-mm thick copper sheet and a 0.5-mm nickel-plated iron sheet]
(No alloy layer is observed at the faying surface, although a plated layer is observed.)
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Copper sheets are bonded together immediately before melting, and are joined by diffusion. No nuggets are
observed under an optical microscope. This welding increases temperature until a molten state is formed.
[Welding of a 0.1-mm thick nickel sheet and a 0.22-mm nickel-plated iron sheet]
(Nickel is trapped in the iron sheet due to a plastic flow.)
1. High thermal efficiency and short weld time ensure clean and neat welding.
A single-phase ac current comes to zero periodically, resulting in intermittent heat supply. An inverter
power supply flows current which is never to be zero, ensuring continuous heat supply. Owing to this,
welding is performed in a short period of time and nugget receives less thermal effect. Consequently,
clean and neat weld is obtained.
2. Spatter is reduced; stable welding is conducted.
Weld time and rise time of weld current are adjustable, corresponding to material and shape of metal.
Weld condition setting not to generate spatter is possible.
3. Small-sized, light-weighted welding transformer is easy to mount on automated machine.
Compared with other welding power supply, welding transformer is small sized.
A. Capacitor welding power supply charges a capacitor once, then discharges to flow a large current at a time.
Owing to the large current, it can weld high-thermal-conductivity material such as aluminum, copper. As it
charges capacitor, input capacity of power supply can be reduced; nevertheless, a stable welding is
performed.
However, current rises steeply and gradient angle of the rising current cannot be controlled, causing a
spatter easily. Electrode force must be increased to reduce the spatter. Precaution against Peltier effect
which is due to direct current is needed.
A. Transistor welding power supply does not need a welding transformer, but performs high-speed control of
welding current directly by means of transistor; so it reduces spatter, ensuring ultra-precision welding. This
power supply is suited for welding such as fine wire, cross wire, high-resistance material; also suitable for
welding micro-electronic parts such as metal foil, contact, battery tab.
A. It is called Rogowskii coil having an air-cored coil. It detects magnetic field generated by current, and
measures current intensity.
This coil is hung on secondary conductor, through which secondary current flows, to use. It is combined with
our Weld Checker for weld quality control.
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A. When dc current flows through two different kinds of metal which contact each other, temperature difference
is generated between positive pole and negative one. This is called Peltier effect. Though this effect is
applied to equipment in which cooling and heat radiation are repeated, uneven wear of electrode and
irregular nuggets are unfavorably generated in welding.
As this effect occurs when current flows constantly in one direction, an ac power supply or polarity-switching
power supply solves this problem.
For more detail, inquire us at:
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A. While it has been used, oxidized film forms at a tip of the electrode to generate heat; meanwhile it comes to
be unable to weld. Also, melted coating of wire and debris of workpiece may stick to the electrode. Since
such a foreign matter causes defective weld, electrode must be ground to remove them every certain
number of welds periodically, corresponding to welding conditions. Furthermore, grinding the electrode is
needed to shape up its tip because contact area increases to change current density.
A. It is to weld such a workpiece that is comprised of plates of which thicknesses are different remarkably. The
thicker workpiece is provided with projection to increase current density; then Joule heat concentrates on
the projection to weld.
[Advantage]
1. Simultaneous multi-point welding is possible.
2. As a flat electrode can be used, lifetime of the electrode is extended.
3. Thicker plate which is 3 times or more as thick as the other one can be welded to a certain extent.
4. If welded at two or more projections, the welds can endure more rotating torque.
5. Maintenance of electrode is easy.
6. Weld time is shorter.
7. Concentrated current results in energy saving.
[Disadvantage]
1. Multipoint welding causes welding facility to be larger (current capacity, weld force).
2. Projections must be leveled.
3. Electrodes must be maintained in parallel severely.
[Secondary-constant-current control]
Secondary current of welding transformer is fed via toroidal coil back to controller in order to be kept
constant. It is the feature that a constant current flows even when resistance of workpiece changes. In
power- supply-voltage fluctuation-compensating control, current varies corresponding to the amount of
workpiece that comes in throat of welding head in metal sheet welding; on the contrary, secondary-
constant-current control flows a constant current.
A. Welding transformer generates large current at low voltage. For example, it can deliver 10A at 200V or
200A at 10V, or 1000A at 2V (Energy are identical: 200V x 10A = 2000VA, 10V x 200A = 2000VA, 2V x
1000A = 2000VA). Theoretically, lower-voltage tap can flow a larger current; practically, however, current
flows by Ohm's law: I (current) = E (voltage)/R (resistance) which shows that E is necessary to a certain
extent to flow large current. Consequently, higher voltage tap can flow larger current for high-resistance
workpiece.
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A. Fusing joint is not to utilize Joule heat generated in workpiece as in resistance welding, but to utilize Joule
heat generated in electrode to remove coating of lead wire, joining lead to terminal through heat cohesion.
If resistance welding is conducted to this joint, terminal will melts down; therefore, adequate welding
conditions must be decided to remove coating, causing cohesion of lead and terminal. Application of current
is commonly done by 2-stage current application: the first stage WELD1 in which terminal is deformed
(preliminary shaping), and the second stage WELD2 in which fusing is performed. If 1-stage current
application is employed, preliminary shaping is to be done by up-slope current.
A. We do not have definite method of condition setting because welding condition depends on such as
material of workpiece, strength you need; however, you have to decide the welding conditions, adjusting
weld time, welding current, and weld force since welding is related to the three.
Poor welds which is often happened and the preventive measures for them
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A. It is the effect that is exerted to workpiece by heat generated in welding. The workpiece may change in
color, discolor, deform, or may be breakable; parts may be degraded.
To reduce the heat effect, heat must be applied to workpiece effectively and welding must be conducted in a
short duration of time. Inverter or transistor welding power supply is another choice.
A. It is effective to weld plated metal. The plating metal is removed in the first stage, pushed off electrode and
cooled in COOL; then, workpiece is welded in the second stage. Projection welding, however, basically
employs one-stage welding.
A. Provide thicker metal sheet with projection; however, if this sheet is 3 or more times thicker than thinner
one, you will have difficulty in welding them.
Q. What should we consider, including weld conditions, before introducing a new micro-resistance welding
system for the first time?
A. First, you should consider whether the metal materials can make a firm alloy by melting together or whether
they can be joined by diffusion. Some combinations of metal materials will always be weak. In this case, you
will have to consider using other materials, or using an insert metal that easily coalesces with both
workpiece metals to form a diffusion bonding.
Second, consider the workpiece shapes at welding points. In order to use resistance welding, workpieces
have to be processed into shapes that allow a constant force and current to be applied. Also, welding
increases the temperature of both metals to their melting points, so their heat capacities (masses) at the
surface of the welding point have to be balanced. In addition, you have to pay attention to the selection of a
plating material.
Third, consider workpiece configuration. You cannot micro-resistance weld together workpieces that are
usually soldered without changing the materials or shapes used. Workpieces that have been soldered are
designed to be soldered; workpieces have to be designed to be resistance-welded in order for a resistance
welding system to be used. To obtain micro-resistance weld conditions with wide margins, workpiece design
is very important, in fact vital, because the bottom-line goal is to maintain stable welding qualities.
Finally, determine the configuration and materials of the workpieces, and at the same time, determine the
method of applying current, or the paths via apply current or force are applied. Usually, three types of
applying current are used: direct, indirect, and series methods which are also used in resistance welding.
The parallel-gap method, similar to the series method, is specifically used in micro-resistance welding. It
does not weld two spots; instead it welds a spot between the electrodes.
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