Spot Welding

Spot Welding
Lesson Objectives
When you finish this lesson you will
understand:
Basics of Resistance Welding Processes
Heat Generation & Control
Spot Welding Process and Applications

Learning Activities
1. View Slides;
2. Read Notes,
3. Listen to lecture
4. View Demo
5. Do on-line
workbook

Keywords: Resistance Spot Welding, Heat Generation,

Equipment Control, Contact Resistance, Upslope, Downslope,
Hold Time, Temper, Squeeze Time, Electrode

Definition of Resistance
Welding
Resistance welding is a fusion welding process in
which coalescence of metals is produced at the
faying surfaces by the heat generated at the joint by
the resistance of the work to the flow of electricity.
Force is applied before, during, and after the
application of current to prevent arcing at the work
piece.
Melting occurs at the faying surfaces during
welding.

Principal Types of Resistance Welds

Electrodes
or Welding
Tips

Electrodes
or Welding
Wheels

Spot Weld

Electrodes
or Dies

Seam Weld

Projection
Welds

Projection Weld

Electrodes or Dies

Upset Weld
After Welding

Flash Weld
After Welding

[Reference: Resistance Welding Manual, RWMA, p.1-3]

Typical Equipment of Resistance Spot Welding

(a)

(b)

[Reference: Welding Process Slides, The Welding Institute]

Advantages of Resistance Spot

Welding

Adaptability for Automation in High-Rate

Production of Sheet Metal Assemblies

High Speed

Economical

Dimensional Accuracy

Limitations of Resistance Spot

Welding

Difficulty for maintenance or repair

Adds weight and material cost to the product, compared with
a butt joint

Generally have higher cost than most arc welding equipment

Produces unfavorable line power demands

Low tensile and fatigue strength

The full strength of the sheet cannot prevail across a spot
welded joint

Eccentric loading condition

Resistance Welding
Resistance welding depends on three
factors:
Time of current flow (T).
Resistance of the conductor (R)
Amperage (I).

Heat generation is expressed as

Q = I2R T, Q = Heat generated.

Heat = I2 RTK
Where
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses

Is a function of:
Transformer Tap Setting
Material Prop., & Pressure
Control Setting
Conduction, Convection,
Radiation

Heating Value of Current = RMS Current

Irms=0.707 Ipeak

Block Diagram of Single-Phase

Spot Welder
Contactor

Main Power Line

Spot Weld

N=np/ns
Vs= Vp/N
Is = Ip N

Heat = I2 RTK
Where
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses

Is a function of:
Transformer Tap Setting
Material Prop., & Pressure
Control Setting
Conduction, Convection,
Radiation

Contact-Resistance Measurement
Electrode
Rec

Force

Small Current
Rec
Rsc

Rtotal

Rec

Rv
Rv

Contact
Area
Rec

Electrode

Force

Rec = contact resistance

between electrode
and sheet surface
Rsc = contact resistance
at the faying surface
Rv = volume resistance of
the sheets

Factors Affecting Heat

Generation (Q):
Welding pressure
as welding pressure increases both R
and Q decrease.
Electrodes
deformation of electrodes increases
contact area. As contact area increases,
both R and Q decrease.

Link to electrode force demo

Surface
Condition
(a) Pickled Conditions
Steel
(b) Rusted Conditions
Oils/Dirt
Oxide

Steel

Resistivity

Steel

Rusty
Polished
Pickled

Oxide
Oils/Dirt

Electrode Force
Steel

Resistance Varies with Pressure

Low Pressure

(a)

Medium Pressure

(b)

High Pressure

(c)

Volume-Resistance Measurement
Electrode

Force

Small Current
Rec
Rsc
Rtotal

Rec

Rv
Rv

Contact
Area
Rv

Electrode

Force

Rec = contact resistance

between electrode
and sheet surface
Rsc = contact resistance
at the faying surface
Rv = volume resistance of
the sheets

Resistivity, -cm

Resistivity as a Function of Temperature

130
120
110
100
90
80
70
60
50
40
30
20
10

HSLA

Low Carbon

100 200 300 400 500 600 700 800

Temperature, C
[Reference: Welding in the Automotive Industry, D.W. Dickinson, p.125]

Heat = I2 RTK
Where
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses

Is a function of:
Transformer Tap Setting
Material Prop., & Pressure
Control Setting
Conduction, Convection,
Radiation

Heating Value of Current = RMS Current

Irms=0.707 Ipeak

Current

Electrode
Pressure

Upslope/Downslope, Hold Time,

& Temper

Weld Current
Temper Current

Upslope
Downslope
Temper
Squeeze Time
Weld Time
Off Time
Hold Time

Heat = I2 RTK
Where
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses

Is a function of:
Transformer Tap Setting
Material Prop., & Pressure
Control Setting
Conduction, Convection,
Radiation

Heat Dissipation
Water-Cooled Copper Alloy Electrode

Base Metal
Weld Nugget

Base Metal

Water-Cooled Copper Alloy Electrode

Heat = I RTK
Where
I = Current (Amps)
R = Resistance (Ohms)
T = Time (Cycles 1/60
Second)
K = Heat Losses

Is a function of:
Transformer Tap Setting
Pressure
Control Setting
Conduction, Convection,
Radiation

Lets put it all together

Initial Resistance Through Weldment

Top Electrode
Water

Distance

Weld
Nugget

Resistance
Bottom Electrode

Temperature Readings of A Spot Welding Process

(Note: Temp at Electrode Sheet Interface Higher than Bulk)

Workpiece

This illustration was taken

about 4/60th of a second
after the welding current
starts.

At the end of
welding time

After 20%
welding time

Electrode

Workpiece

Temperature
distribution
at
various
location
during
welding.

Electrode

Temperature Distribution

Temperature

Link to nugget growth demo

Nugget Solidification