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DEPARTMENT OF TECHNICAL EDUCATION

ANDHRA PRADESH
• Name : V.SRINIVASA RAO
• Designation : Lecturer
• Branch : A.E.I.E
• Institute : Govt. Polytechnic for women,
Srikakulam
• Semester : VI
• Subject : Industrial Electronics, PLC and SCADA
• Subject code : AEI-602
• Topic : Industrial Heating and Welding
• Duration : 100 min
• Sub topic : Principle of Resistance Welding .
• Teaching aids : ppt, photographs, diagrams.
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OBJECTIVES

After completion of this lesson the student will be


able to know

• Principle of Resistance welding Process

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WELDING

• Welding is a metallurgical process by which


metals are joined together by the application of
heat and pressure
or

• Welding is the process in which metals are heated


to melting point and adhere on solidification.

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RESISTANCE WELDING

• Electric Resistance welding is the process of


fusing two or more metal pieces together by
passing A.C or D.C current of high value that flows
for a short duration through the area of contact.

• The duration of the current is varied from few milli-


seconds to several seconds depending on the job
requirement.

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RESISTANCE WELDING…
• In Resistance welding, the heat required to weld is
produced by the resistance offered to the flow of
current at the junction of the metals to be joined.
• The heat energy produced is given by

Where r = Resistance of entire circuit


I = Instantaneous current
t = Time duration of welding process.

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RESISTANCE WELDING…

Since the junction resistance is very small, hence


very large amount of current of more than 1000 A
will flow at a voltage of 1V to 15V.

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PRINCIPLE OF RESISTANCE WELDING
• Two metallic pieces to be welded together are
pressed against each other by two electrodes of
Resistance welding unit.
• A high current is made to flow between two
electrodes
• This current produces large heat due to I2R loss,
where R is the contact resistance between the
metal plates.

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Principle of Resistance Welding…

Electrode 1
Current i
Metal sheet 1

Region of spot welding

Metal sheet 2 Electrode 2

Fig.1
PRINCIPLE OF RESISTANCE WELDING…

• As a result of localized melting occurs and two


pieces are fused together at that point

• Now the current is stopped but the pressure is still


retained

• The fused portions cool down and get welded to


each other.

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Advantages of Resistance welding

• Very high efficiency

• It does not require external heat source

• Homogeneous weld is produced

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Advantages of Resistance welding

• Clean, Strong weld is produced

• Heat is generated within the job it self

• Short time is required for welding operation

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Differences among Industrial Heating Process
Sl. Induction Di-electric Resistance
No. Heating Heating Heating
1 Established Recent Oldest Method
Method Method
2 Frequency Frequency Frequency
dependant dependant Independent

3 Complex Complex Simple


Procedure Procedure Procedure

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Differences among Industrial Heating Process
Sl. Induction Di-electric Resistance
No. Heating Heating Heating
4 Work Piece is Work Piece is Work Piece is
Conductor Non-Conductor Metal

5 Requires high Requires high Holds good for


Voltage and Voltage and both A.C and
High High D.C power
Frequency Frequency supplies

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SUMMARY

We have discussed about

• Principle of Resistance welding Process

• Advantages of Resistance

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QUIZ

3. Which is the Application of Di-electric Heating among


the following choices.
(a) Preheating and curing of plastics.
(b) Gluing, drying and curing of wood
(c) Sewing of Plastic Films
(d) All of the above

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QUIZ

3. Resistance welding performed at

a) High Voltage, High Current

b) Low Voltage, High Current

c) Low Voltage, Low Current

d) High Voltage, Low Current

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Frequently Asked Questions

• Explain the Principle of Resistance Welding.

• List the advantages of Resistance Welding.

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