What Is Resistance Welding?

Did you know that Resistance Welding is one of the most used welding processes demonstrated in the manufacturing industry today? This process accounts for almost 70 percent of all metal joining applications used in the automobile and aerospace industries alone.

On top of that, it is estimated that bodywork applications of this process make up an impressive 67 million welds per year in the US alone! So, what exactly is Resistance Welding? In this article, we will examine the fundamentals of this process and how it works.

What is Resistance Welding?

Resistance welding is a process of joining two pieces of metal together using electrical resistance. It utilizes pressure and electric current to generate heat in an area of the two pieces that are in contact, and eventually cause them to fuse together.

The primary benefit of resistance welding is that it offers an efficient and cost-effective method of permanently joining two separate pieces of metal together.

The Resistance Welding Process

The resistance welding process typically includes three critical components: pressure, current, and heat.

The two pieces of metal are clamped between two electrodes, and electric current is passed through them. As the current passes through, it creates heat that softens and melts the surfaces of both pieces, allowing them to be joined together. The pressure of the electrodes helps to spread and fuse the melted metal along the joint.

Types of Resistance Welding

The two most common types of resistance welding are spot welding and seam welding. Spot welding is a method that utilizes spot electrodes to create an electrical arc between the two pieces of metal.

The arc is then used to heat up a smaller area of the metal, and pressure is applied to the area to help join the two pieces together. Seam welding, meanwhile, joins two pieces of metal by running a continuous electrical arc along the length of the two pieces while they are pressed together. This type of welding is most effective for joining materials with thick edges, as the heat is distributed along the entire length of the joint.

Advantages of Resistance Welding

Resistance welding is an effective method of joining two pieces of metal together, and it has numerous advantages compared to other types of welding. One of the primary benefits of resistance welding is that it offers a more efficient and cost-effective process than other types of welding.

Additionally, the process is considered to be greener than other welding processes, as it requires a significantly lower amount of energy and produces fewer emissions. Finally, the process is relatively simple and can be completed within a short period of time, meaning that it is a great option for high-volume industrial applications.


Resistance welding is a cost-effective and efficient method of joining two separate pieces of metal together. The welding process utilizes pressure, electric current, and heat to create a strong connection between two pieces of metal. Spot welding and seam welding are the two most common types of resistance welding, and they each offer unique benefits. As compared to other types of welding, resistance welding is generally considered more efficient, cost-effective, and environmentally-friendly. Citation URL: – https://www. theengineer. co. uk/resistance-welding/- https://weldstar. com/blog/what-is-resistance-welding- https://www. brighthubengineering. com/manufacturing-mechanical-design/44558-fundamentals-of-resistance-welding/

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