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Resistance Welding

Resistance welding is defined as a process whereby force is applied to surfaces in contact and in which the heat for welding is produced by the passage of electric current through the electrical resistance at, and adjacent to, these surfaces. 

Resistance welding is a well-established process, having an excellent track record for producing quality joints in sheet materials. In the European automotive industry alone, over 150 million resistance spot welds are made each day.

Many variations of the resistance welding process exist; commonly resistance welding techniques are divided into the following categories:

  • Resistance spot welding
  • Resistance projection welding
  • Resistance seam welding
  • Flash and resistance butt welding
  • High frequency welding
  • Micro and miniature resistance welding
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Resistance Welding

Industrial applications

Resistance welding is used in applications across a wide range of industry sectors including white goods, automotive, heating and ventilation, aerospace and construction.

Due to its high speed and reliability resistance welding is particularly suited to mass production, the most commonly used process variant is resistance spot welding. Spot welding is primarily used to join metal sheet, the process can accommodate a wide range of materials and thicknesses, usually between 0.5 – 5.0mm. Materials that can be spot welded include: low carbon steels high strength steels, press hardened steels, stainless steels, nickel alloys, aluminium alloys, titanium alloys, copper and its alloys, magnesium and some refractory metals.

Resistance welding at TWI

TWI has longstanding, industry-based experience in resistance techniques, and has developed process and quality standards. A comprehensive technical support service is provided and project work has included: troubleshooting & advice on best practice, development of new and novel techniques, fracture mechanics testing facilities, metallurgical support services, instrumentation & monitoring equipment, tailored training courses.

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For further information or if you have any questions please do not hesitate to contact us.