Umair Gaines
Electric resistance welding (ERW) is a welding process that uses electric current to heat and join metal parts. The process involves applying an electric current to the metal, which generates heat due to the electrical resistance at the point of contact. This heat causes the metal to soften and eventually melt, forming a molten or plastic state that can be shaped and welded together. The weld joint is then created by applying pressure to the semi-molten surfaces, resulting in a strong and uniformly welded structure. ERW is widely used in various industries, including automotive manufacturing, aviation, and the production of steel pipes and containers. Different types of ERW include spot welding, seam welding, projection welding, and butt welding, each with its unique applications and advantages.
| Characteristics | Values |
|---|---|
| Definition | A thermo-electric cycle in which intensity is created at the edge planes of welding plates as a result of electric resistance and a weld joint can be made by applying low-strain to these plates. |
| Process | Metal parts are carried into contact with one another, sandwiched between two electrode tips. |
| Heating | The electric current heats the metal to its melting point. |
| Cooling | Water-cooled copper electrodes are used to remove surface heat quickly. |
| Types | Spot welding, seam welding, flash welding, projection welding, butt welding, HF contact welding, rotary contact wheel welding, AC rotary contact wheel welding, DC rotary contact wheel welding. |
| Uses | Widely used in the manufacturing industry for joining metal sheets and components, e.g. in the automotive, aviation, electrical, and electronics industries. |
| Advantages | High precision, strength, and efficiency; pollution-free. |
| Disadvantages | Limited by material thickness and equipment costs; current and heat may vary, limiting welding speed; may be susceptible to seam corrosion, hook cracks, and inadequate bonding of seams. |
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What You'll Learn
Spot welding
Electric resistance welding (ERW) is a welding process in which metal parts are joined by heating them with an electric current, melting the metal at the joint. This process is widely used in the manufacture of steel pipes and in the assembly of automobile bodies.
The amount of heat delivered to the spot is determined by the resistance between the electrodes and the magnitude and duration of the current. The amount of energy must be chosen to match the material properties, thickness, and type of electrodes. Applying too little energy will result in a poor weld, while applying too much energy will eject molten material and create a hole.
The equipment used in spot welding consists of tool holders and electrodes. The tool holders function as a mechanism to hold the electrodes in place and support optional water hoses that cool the electrodes during welding. The electrodes are generally made of a low-resistance alloy, usually copper, and are designed in various shapes and sizes depending on the application.
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Seam welding
Electric resistance welding (ERW) is a welding process in which metal parts are joined by heating them with an electric current, melting the metal at the joint. This process is commonly used in the manufacture of steel pipe and in the assembly of automobiles.
The seam welding process begins with the metal parts being carried into contact with one another, sandwiched between two electrode tips. These electrodes are responsible for applying the requisite pressure to ensure optimal contact and to firmly hold the parts intact during welding. The weld timing and cathode development can be controlled to ensure that the weld cross-over and work part doesn't get too hot. Seam welding is a quick welding interaction and it can be computerized using mechanical machines.
There are two modes for seam welding: intermittent and continuous. In intermittent seam welding, the wheels advance to the desired position and stop to make each weld. In continuous seam welding, the wheels continue to roll as each weld is made.
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Projection welding
Electric resistance welding (ERW) is a welding process that joins metal parts by heating them with an electric current, melting the metal at the joint. The weld is formed by applying pressure to the joint. Some common types of ERW include spot welding, seam welding, flash welding, and projection welding.
In projection welding, the force should be set to create a small indent at the projection tip before the weld is fired. This force is typically held constant throughout the weld but can be increased towards the end to provide a forging action. The weld timing and cathode movement can be adjusted to ensure the weld cross-over and workpiece do not get too hot. The delivery of high power in a short time can lead to arcs, sparks, and electrode sticking, so most active welding and process tweaking is done at a slightly lower power level.
The total energy required for projection welding is the same as for other resistance welding methods, but the rate of energy delivery is critical. The process window size can be increased by selecting the appropriate materials, part design, welding equipment, and process parameters. Projection welding is commonly used on welding nuts and to make circumferential projections to form a hermetic seal.
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Flash welding
Electric resistance welding (ERW) is a welding process in which metal parts are joined by heating them with an electric current, melting the metal at the joint. This process is widely used in the manufacture of steel pipe and in the assembly of automobile bodies.
The main components of the flash welding process are the power supply, welding transformer, clamps, and cooling system. An AC power supply provides the power, while the welding transformer changes the current and voltage. Two clamps are used: a stationary clamp that remains fixed and a movable clamp that moves about its axis. Finally, a cooling system is necessary to avoid overheating and guarantee that the welded joint cools effectively without deforming the material.
Overall, flash welding is a quick, consistent, and adaptable welding method that can produce strong welds in a variety of materials.
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Brazing
Electric resistance welding (ERW) is a welding process that involves joining metal parts by heating them with an electric current, melting the metal at the joint. This process is commonly used in the manufacture of steel pipes and in the assembly of automobile bodies.
While brazing shares similarities with welding and soldering, there are distinct differences. Soldering, for instance, typically involves lower temperatures and is commonly used for joining delicate or thin materials such as electronic components. Welding, on the other hand, fuses the base metals to create a stronger joint than brazing, making it preferable for applications requiring permanent bonds that can withstand high stresses and temperatures.
In summary, brazing is a versatile and efficient joining process that offers advantages over welding and soldering in certain applications. It is particularly useful for joining dissimilar metals, preserving mechanical properties, and achieving quick cycle times with low thermal distortion.
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Frequently asked questions
Electric resistance welding (ERW) is a welding process in which metal parts are joined by heating them with an electric current, melting the metal at the joint.
The five types of electric resistance welding are seam welding, spot welding, projection welding, butt welding, and flash welding.
Seam welding uses two roller electrodes to join overlapping metal sheets. The pressure remains constant, and a continuous joint is achieved through this method.
Spot welding is used to join two or more overlapping metal sheets, studs, projections, electrical wiring hangers, some heat exchanger fins, and some tubing.
Electric resistance welding is precise, efficient, and pollution-free. However, it has few applications due to limitations in material thickness and equipment costs.
