The Four Major Resistance Welding Processes: How To Use Spot Welding, Seam Welding, Projection Welding, And Butt Welding?

In metal welding scenarios in factories, different welding processes cater to different needs, much like how different tools solve different problems. Resistance welding mainly includes four processes: spot welding, seam welding, projection welding, and butt welding, each with its own characteristics and advantages. Below is a detailed introduction to their working principles, application scenarios, and the role of PDKJ equipment.

1. Spot Welding: A Fast and Precise Metal Connection Method

Spot welding works by pressing two metal sheets together with electrodes and then passing electricity through them instantly. This generates high heat at the contact point, causing localized melting and fusion of the metal to form an independent weld nugget. This welding method is simple to operate and can complete the welding of one spot in an instant.

The biggest advantage of spot welding is its speed and flexibility. PDKJ's intelligent spot welding machine can weld a single spot in just 0.02 - 0.2 seconds. It can also adjust the welding current and pressure according to the thickness and material of the metal. With precise parameter control, it effectively avoids false welding and missed welding, ensuring stable weld quality.

In practical applications, spot welding is widely used in automobile manufacturing and home appliance production. For example, the body - in - white of a car is assembled through thousands of spot welds to ensure the structural rigidity of the body. The shells of refrigerators and washing machines are also quickly assembled through spot welding, improving production efficiency.

2. Seam Welding: Achieving Continuous Sealed Welding

Seam welding can be seen as an extension of spot welding. It uses two rotating disk - shaped electrodes to press metal sheets together while continuously passing electricity, forming a series of overlapping weld spots that ultimately form a continuous weld seam.

The prominent feature of seam welding is its ability to achieve good sealing effects. PDKJ's seam welding equipment uses stable servo motors to drive the electrodes and combines precise current control to ensure uniform and strong weld seams. This effectively prevents leakage of liquids and gases. Products with high sealing requirements, such as fuel tanks, beverage cans, and natural gas pipelines, are welded using the seam welding process.

3. Projection Welding: An Efficient Welding Solution for Multiple Spots

Projection welding is similar in principle to spot welding, but before welding, protrusions are processed on the welding spots of the workpiece. During welding, the current is concentrated through the protrusions, causing the metal at the protrusion sites to melt rapidly and form weld spots, thus achieving simultaneous welding of multiple spots.

Projection welding greatly improves welding efficiency and is particularly suitable for scenarios requiring multiple spot connections. For example, in the production of outdoor unit brackets for air conditioners, projection welding can complete multiple spot welds in one go, significantly improving efficiency compared to individual spot welding. PDKJ's projection welding machines are equipped with various electrodes and fixtures to adapt to different shapes and sizes of protrusions, ensuring welding quality.

4. Butt Welding: A Reliable Process for Metal Jointing

Butt welding is a welding method that connects two pieces of metal along their contact surfaces and is mainly divided into resistance butt welding and flash butt welding. Resistance butt welding involves bringing the metal ends into close contact, heating them to a plastic state, and then applying forging force to complete the welding. Flash butt welding, on the other hand, first allows slight contact between the metal ends to produce a flash, removing surface impurities, and then applies forging force to complete the welding.

PDKJ's butt welding equipment has strong current output and precise pressure control. The welded joints have high strength, almost approaching the strength of the base metal. In the construction industry, butt welding is commonly used for reinforcing bar extension. The welding of bicycle and motorcycle frames also relies on butt welding to achieve precise jointing of tubes.

Summary: Choose the Right Resistance Welding Process Based on Needs

The four resistance welding processes—spot welding, seam welding, projection welding, and butt welding—each have their advantages. The choice of process depends on specific welding requirements. With years of experience in the resistance welding equipment field, PDKJ has developed high - performance equipment for different processes. Whether you need fast spot welding, sealed seam welding, efficient projection welding, or strong butt welding, PDKJ can provide suitable solutions. If you have welding - related needs, feel free to contact us for professional welding - solution suggestions.

If you have welding machine requirements, please contact Ms. Zhao

E-Mail: pdkj@gd-pw.com

Phone: +86-13631765713