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Technical advantages of resistance welding [RW08]
Dec 29,2023
Technical advantages of resistance welding
When I talk to other welding experts about resistance welding, I usually get this comment: “I know this is a real welding process, but it only works on making cars.”That's a little offensive to welders like me.
There are many applications for resistance welding. It can be used to make rockets and jet engine, rocket fuel tanks, water tanks, artificial pacemaker, cell phones, computers, circuit breakers, wiring harnesses, satellite navigation, trucks, cars, Recreational Vehicles and tractors, wheels, railways, rails, concrete and steel, sea platforms, bridge gratings, metal frames, home appliances, tools, office and outdoor furniture, coffins, school buses, ambulances, electric vehicle batteries. It could also be used to build Gemini, Apollo and Atlas spacecraft.
Let's be more professional.
When welding truck rims, we can use arc welding or resistance welding. However, compared with resistance welding, ARC welding truck wheel costs 20% -30% higher, welding speed is 50% slower, because the arc welding wheel needs more finishing, quality inspection, smoke removal and filling metal.
Resistance welding as an alternative, the quality of its welded wheels are more durable, better fatigue performance. In addition, resistance welding butt joints do not add metal to change the metallurgy. Since welding is performed under pressure, there is little, if any, gas trapped to form pores. The butt joint is perfectly flush with the base metal (which means it is less likely to crack during subsequent rolling). No melting or laser welding can do like that. This is not to say that arc welding of the wheel does not have any advantages. Arc welding is a very good process, and its main difference from resistance welding is welding cost, welding speed, welding quality and the long-term durability of the welding parts.
This example can also be applied to the seam welding of a rocket fuel tank. Resistance welding of welds in large booster or fuel tank of rocket is cheaper and more effective than arc, friction stir welding welding or even laser welding. The application of resistance welding may have some limitations depending on the thickness of the fuel tank, but the thinner the base metal, the better the effect of resistance welding.
Final thoughts
Resistance welding should be the first choice for design, application, and process engineers who are struggling with the question of which welding process to choose. Learn more about resistance welding applications and get yourself out of your head so that all the welding techniques are at your fingertips.
I'll end this conversation by asking the original question: Why not choose resistance welding? Why not choose a cheaper, faster, better quality welding method? Why not be like the smartest man in history?
Note:
This article is adapted from the 7th issue of Welding Journal column Question and Answer. The answer is from Don DeCORTE.
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Wuxi HAIFEI Intelligent Equipment Co., Ltd.
Wuxi HAIFEI Welding Equipment Co., Ltd.
Add: 28 Shuiyun Road, Yuecheng, Jiangyin, Jiangsu Province, China. (Postal Code: 214404)
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Email: wushijie@jshaifei.com