Resistance welding principles and advantages and disadvantages

Principle of resistance welding

DC inverter resistance spot welding machine is a process that achieves welding through the resistance heat generated when current passes through the welded parts. The basic principle is: during welding, two pieces of workpieces to be welded are placed between electrodes, and the electrodes are pressurized and passed with high current. Due to the resistance of the material, the heat generated when the current passes causes the workpiece to melt locally, thus forming a weld joint. After the current stops, the pressure is maintained, and the welded area is cooled and solidified to complete the welding.

There are several main forms of resistance welding, among which the most common are wire spot welding, seam welding and roll welding. Spot welding is to form a weld nugget by locally heating the workpiece, thereby welding the workpieces together, which is suitable for connecting thin plates.

Advantages

1. **High speed and high efficiency**: Resistance machine welding can achieve fast and continuous welding, which is suitable for large-scale production. Due to the small heating area, low heat input and concentrated energy, the welding task can be completed quickly.

2. **No need for filler material**: The resistance welding process usually does not require filler material, reducing material consumption and cost.

3. **High welding strength**: The welded joint is strong and can withstand high loads, especially suitable for welding thin metal sheets.

4. **High degree of automation**: Resistance welding is suitable for automated production lines, which can improve production efficiency and reduce labor costs, especially suitable for industries such as automobile manufacturing.

5. **Wide range of application**: Precision resistance welding machine can weld a variety of materials, including steel, aluminum, copper and other metals, especially widely used in body welding in the automotive industry.

Disadvantages

1. **Limited material thickness**: Resistance welding is usually suitable for thin plates or medium-thick metals, and has limited welding capacity for thicker materials. For thick plate welding, stronger equipment and more current are required.

2. **Poor appearance of welded joints**: Since the weld point is formed by local melting, the appearance of the welded joint may be rough and require additional treatment.

3. **Large equipment investment**: The initial investment of resistance welding equipment is high, especially welding equipment with a high degree of automation.

4. **Electrode wear problem**: Due to the continuous contact between the electrode and the workpiece, the electrode head will gradually wear, affecting the welding quality, and the electrode needs to be replaced or repaired regularly.

5. **Local deformation**: Due to the high temperature concentration during welding, thermal stress is easily generated, which leads to local deformation of the workpiece. The heating and cooling process needs to be controlled.

Summary

Resistance welding, as an efficient and energy-saving welding process, is widely used in the automotive, home appliances, electronics and other industries, especially in mass production. Although there are some limitations, such as the requirements for material thickness and high equipment investment, these shortcomings are being effectively solved with the advancement of technology.

As a resistance welding equipment manufacturers, we are confident that similar products will surpass Miyachi weld controller and Bosch weld controller

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