Projection Welding Machines

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Spot welding (or resistance spot welding^[1]) is a type of electric resistance welding used to weld various sheet metal products, through a process in which contacting metal surface points are joined by the heat obtained from resistance to electric current.

The process uses two shaped copper alloy electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the sheets together. Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in the 0.5 to 3 mm (0.020 to 0.118 in) thickness range. Forcing a large current through the spot will melt the metal and form the weld. The attractive feature of spot welding is that a large amount of energy can be delivered to the spot in a very short time (approximately 10–100 milliseconds).^[2] This permits the welding to occur without excessive heating of the remainder of the sheet.

The amount of heat (energy) delivered to the spot is determined by the resistance between the electrodes and the magnitude and duration of the current.^[3] The amount of energy is chosen to match the sheet's material properties, its thickness, and type of electrodes. Applying too little energy will not melt the metal or will make a poor weld. Applying too much energy will melt too much metal, eject molten material, and make a hole rather than a weld.^[4] Another feature of spot welding is that the energy delivered to the spot can be controlled to produce reliable welds.