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 : Different Resistance Welding
Processes
A.C Resistance Welding, Applications
AEI602.29to30 1
• Teaching aids : ppt, photographs, diagrams.
 OBJECTIVES

After completion of this lesson the student will be

able to know

• Different types of Resistance Welding Processes.

• Circuit of A.C Resistance Welding and its working.

• Applications of Resistance Welding

AEI602.29to30 2
TYPES OF RESISTANCE WELDING

1. Spot Welding
Electrode 1
Current i
Metal sheet 1

Region of
spot welding
held
Metal sheet 2 Electrode 2

Fig.2
 SPOT WELDING

• Spot welding is done by clamping together

between two pointed electrodes, two or more
pieces of metal usually in the form of sheets

• The pointed electrodes ensure proper localization

of current

AEI602.29to30 4
2. Projection Welding

Electrode

Bump

Electrode

Fig.3
 PROJECTION WELDING…

• In this welding process, for concentration of heat,

one electrode is made of either an embossing or
raised pump, on one or both of the pieces at a
location where welding is desired.

• The arrangement is shown in the figure.

AEI602.29to30 6
3. Butt welding

electrodes

Welded portion

Fig.5
 BUTT WELDING…

• In this welding, the two ends of two bars, rods or

tubes to be welded are firmly butted together as
shown in the figure

• Current passing through the Butt raises the

temperature.

AEI602.29to30 8
 BUTT WELDING…

• When the desired temperature is reached, the

two pieces are rammed together either manually
or automatically resulting in a weld.

• Butt welding can be used to weld together bars

of diameters up to several centimeters.

AEI602.29to30 9
4. SEAM WELDING

ROLLER ELECTRODE

METAL SHEET

Fig.4
 SEAM WELDING…

• In this welding, two over lapped sheets of metal

are welded together.

• They welded along a continuous line by moving

them between two wheel shaped electrodes
through which the welding current flows at short
intervals.

AEI602.29to30 11
 5. FLASH BUTT WELDING

In this welding
• The butting surfaces are repetitively brought in to
contact with each other.

• This produce intense heat of arc at the welding

surface which is followed by forging pressure that
completes the weld.

• Flash butt weld is used for welding rail ends, rolled

sections, and shaft axles.

AEI602.29to30 12
 6. PULSATION WELDING

• It is a variation of spot welding.

• In this welding, the welding current flows

intermittently

• This permits the water cooled electrodes to

remove heat from the surface of the material there
by causing higher temperature gradient near the
weld.

AEI602.29to30 13
 A.C RESISTANCE WELDING

Block Representation of an AC Resistance Welding Scheme

AEI602.29to30 14
 A.C RESISTANCE WELDING

• Welding machine receive ac power by means of a

timing device, through a power transformer, a circuit
breaker, and an SCR or ignitron contactor.

• The welding transformer in side the welding

machine reduces the voltage at the electrode tips up
to 1V to 10V and supplies large amount of current at
about 50A to 2000A.

AEI602.29to30 15
 A.C RESISTANCE WELDING…

• The electrodes are water cooled and must kept

clean

• A solenoid valve applies air pressure to the

electrodes for bringing then together and

squeezing the work pieces properly.

AEI602.29to30 16
 A.C RESISTANCE WELDING…

• Welding piece current then flows to heat the work

piece and make the weld.

• The work piece is held under pressure for a few

moments until the weld is harden

AEI602.29to30 17
Basic circuit for A.C. Resistance Welding

Fig 6
AEI602.29to30 18
 A.C. Resistance Welding

• The line voltage is applied through the SCR or

ignitron contactor

• A thyrite resistor is connected across the

primary to prevent the transient voltages.

AEI602.29to30 19
 A.C. Resistance Welding…

• The welding transformer secondary is connected

to the welding electrodes

• During welding process the circuit will provide

controlled low voltage at very high value of current
to the electrodes.

AEI602.29to30 20
 Applications of Resistance welding

• Used for making pressure tight & leak proof tanks

• Used for fabricating barrels

• Used in Exhaust systems

• Used for welding rail ends

• Used for welding rolled sections

AEI602.29to30 21
 Applications of Resistance welding…

• Used for shaft axles

• Used for welding rods, pipes and wires

• Used for production works

• Used for making lap and butt joints

AEI602.29to30 22
 Resistance welding

Fig.6
 Resistance welding

Fig.7
 IDENTIFYING THE SEAM
Seam welding

Fig.8
Laser welding

Fig.9
SPOT WELDING

Fig.10
Spot / Projection Welder Seam Welder

Fig.11
Resistance welding Equipment

Fig.12
 Spot welders
PLACING ON THE SPOT

Fig.13
 SUMMARY

We have discussed about

• Different types of Resistance Welding Processes

• Circuit of A.C Resistance Welding and its

working

• Applications of Resistance Welding

AEI602.29to30 31
 QUIZ

3. The purpose of Thyrite resistor in the circuit if

A.C Resistance welding is to
(a) Prevent the transient voltages in the primary of
welding transformer
(b) Reduce the welding current.
(c) Sewing of Plastic Films
(d) All of the above

AEI602.29to30 32
 QUIZ

• Resistance welding is used for

a) Fabricating barrels

b) Welding rail ends

c) Shaft axles

d) All of above

AEI602.29to30 33
 Frequently Asked Questions

3. Explain different types of Resistance welding

processes

5. Explain the operation A.C Resistant Welding Circuit

7. List the applications of Resistance Welding.

AEI602.29to30 34