Types of Resistance Welding:

3. Projection Welding: Projection welding is a resistance welding process that produces

coalescence by the heat obtained from the resistance to the flow of the welding current.
The resulting welds are localized at predetermined points by projections, embossments
or intersections.

Projection welding uses the same equipment as spot welding. The only difference is that the
electrodes used are flat on the ends and larger in diameter than the flat electrodes used in spot
welding. Successful projection welding depends greatly on the surface preparation of the pieces
to be welded. Projections, small deformations that will touch the surface of the material to be
welded, are made on the weld areas. One of the main advantages of these projected points is
that welding area can be located easily, which makes projection welding a high-production
welding technique. As the current flows through the two parts to be welded, the projected points
are the main contact area. Whenever a point or projection touches the metal, a weld nugget will
start. These weld points soon reach the plastic state, and the force applied by the electrodes
finishes the weld nugget. The cycle time is the same as the spot-weld time. As the points reach
their plastic state, the metal is compressed so that the finished weld is like the spot weld except
for the small indentations created by projections. When the raised portions touch the second
workpiece of metal, the electric current flows through the contact points, which heats and fuses
the two metal workpieces together.
Projection welding has the following advantages over spot welding:
• Projection makes the welding process simple.
• It is possible to join several welding points in projection welding.
• More output is obtained since more than one weld are done at a time.
• Electrode life is increased due to use of low current density and low pressure.
• Good finished appearance is obtained as surface remains unidented by the electrodes.
• Welds are automatically located by the position of projections.
• As the electrodes are flat, therefore the contact area over the projection is sufficient. It
facilitates the easier maintenance of electrodes, alignments of parts and construction of
various jigs and fixtures.
• With the projection welding, it is easy to weld certain parts which cannot be welded by
spot welding.
Projection welding is particularly applicable to mass production work, e.g., the welding of
refrigerator condensers, crossed-wire welding, refrigerator racks, gratings, grills etc.
4. Butt Welding:
Butt welding is one of the simplest and versatile resistance welding process. In the butt welding
process, heat is produced by the contact resistance between two metal workpieces. The faces
of the workpieces should be machined or edge prepared.
The circuit diagram for butt welding process is shown in the figure.

In butt welding, the two workpieces are brought together and mechanical pressure is applied
along the axial direction by a spring.
There are two types of butt welding,
1) Upset butt welding.
2) Flash butt welding.
 (i) Upset Butt Welding:

It is a resistance welding process that produces coalescence over the entire area of
faying surfaces or progressively along a butt joint by the heat obtained from the
resistance to the flow of welding current through the area where those surfaces are
in contact. It can be used only if the parts to be welded are equal in cross-sectional
area.

The faces of the metal pieces to be joined are prepared for even contact. The metal pieces to be
joined are fixed in clamps and butted squarely against each other, as shown in figure and heavy
current is passed through them. In this case heating is obtained by the contact resistance of the
metals to be welded. When sufficient heat is developed, the pieces are rammed by force to
complete the weld. Pressure is applied either manually or with toggle mechanism. The pressure
applied upsets or forges the parts together. The joint is cooled under pressure. After cooling,
the force is released and the weld is completed. Upset butt welding, which has the advantage
of creating no flash spatter and a smooth and symmetrical upset, is used principally on non-
ferrous materials for welding bars, rods, wire, tubing, formed parts etc. The voltage required
for welding is 2-8 volts and current varies from 50 A to several hundred amperes, depending
upon the material and the area to be welded at a time. The current, pressure and time may be
manual or automatic controlled.
(ii) Flash Butt Welding:
Even though it is not a resistance welding process, it is desirable to consider it here, as in this
method the two metal pieces are butted together and a current is passed through the joint which
heats the ends to red hot. Flash welding may be defined as a resistance welding process that
produces coalescence at the faying surfaces of a butt joint by flashing action and by application
of pressure after heating is substantially completed.
In this process of welding no special preparation of the faces to be welded is necessary. In flash
butt welding the voltage to the metal parts to be joined together is applied before putting them
together. Protruding small parts of the faces to be welded are brought into contact; the heat
developed owing to high resistance of the contact areas raises the temperature of the material
at these points and causes them to melt. The molten metal is blown out, and a small arc is
formed which raises the temperature of adjoining parts of the abutting surfaces. The ejection
of molten metal from high spots continues until the whole of the surfaces are heated to the
welding temperature. Some additional heat may be created by the combustion of molten
particles, the forceable action of which is probably due to the pressure of metallic vapour. The
flashing action is aided by an oscillating movement of one of the components. As soon as the
whole of the surfaces to be welded reach forging temperature, the pressure is applied, and the
power supply is cut off.
Applications of Flash Welding:
a. Flash welding is applied primarily in the butt welding of metal sheets, tubing, bars,
rods, forgings, fittings etc.
b. Flash welding finds applications in automotive and aircraft products, household
appliances, refrigerators, and farm implements.
c. The process is also used for welding the band-saw blades into continuous loops, and
joining of tool steel drill, tap and reamer bodies to low carbon steel and alloy steel
shanks.
d. Flash welding is used to produce assemblies that oth-erwise would require more costly
forgings or castings.

5. Percussion Welding:
Percussion welding is a resistance welding process where in coalescence is produced
simultaneously over the entire area of abutting surfaces by heat obtained from an arc produced
by a rapid discharge of stored electrical energy. This is a self-timing spot welding method.
In this percussion welding process, the pieces to be welded are held apart, one in a stationary
holder and the other in a clamp mounted in a slide and backed up against heavy spring pressure.
When the movable clamp is released, it moves rapidly carrying with it the piece to be welded.
When the two pieces are about 1.5 mm apart, there is a sudden discharge of electrical energy,
causing intense arcing between the two surfaces and heating them to high temperature. As
pieces meet each other under heavy pressure the arc is extinguished due to the percussion blow
of the two parts and the force between them effects the weld.
This percussion welding process is quite like flash welding and upset welding, but is limited to
parts of the same geometry and cross section. It is more complex than the other two processes.
Applications:
Percussion welding process can be used for welding many dissimilar metals. It is used for very
specialized applications and the process is entirely automatic. Metals which can be percussion
welded include, copper alloys, aluminium alloys, nickel alloys, low-carbon steel, medium-
carbon steel, and stainless steels. This process is used for welding satellite tips to tools, copper
to aluminium or stainless steel, silver contact tips to copper, cast iron to steel, lead-in-wires on
electric lamps and zinc to steel. Gold, silver, copper-tungsten, silver-tungsten, and silver-
cadmium oxide percussion welded to copper alloys for commonly used assemblies for electric
contacts.