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Resistance Welding

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Resistance welding is a process that utilizes electricity, and mechanical pressure along with the inherent electrical conductivity (resistance) of the work-pieces to form a weld joint. Electric current is delivered to the work pieces through electrodes and converted to heat that produces instantaneous melting and joining of the work-pieces.

Resistance Welding

Resistance Welding

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This relation shows the sensitivity of the heat produced to the electric current applied; doubling the current (amps) will result in a fourfold increase in heat produced at the weld. Heating continues until the materials to be joined are fused by melting; the addition of pressure applied through the electrodes completes the fusion process. The final function of the electrode utilizes the relatively high thermal conductivity of the electrode material to extract heat from the molten weld area to form a solidified weld nugget. Water cooling is often utilized to remove the heat and cool the molten nugget along with the electrodes.

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