The Mechanical Process of Resistive Welding

For many people, the shower of sparks from the resistive welding machines in many industrial processes is a lasting introduction to the technique. Even when they do not know what they are looking at, many understand that they are witnessing one of the most refined and time tested industrial processes in recent history.

Resistive welding remains one of the most popular processes in fabrication simply because it is very cost effective and easy to integrate within larger processes. The ability to function either stand alone or as part of a larger process means that the designer is able to take advantage of the process without compromising the efficacy and effectiveness of the larger process.

Resistive Welding Equipment

Over years, resistive welding equipment has undergone a lot f refinement a newer and better ways of utilizing the theory of the process emerged. Today, a typical resistive welding setup comprises of the following components.

A frame that houses the electrical supply and transformer. This transform allows the machine to be hooked up to the electricity supply grid without any major modifications.

A set of electrodes that pass the current to the work pieces. There are several popular shapes of electrodes, each designed for a particular use. These electrodes are often directly connected to the transformer so that they are able to transfer the modified electric current directly to the work piece.

A device that controls the pressure on the work piece. This device usually houses the electrodes and ensures that the work piece is under constant pressure. This device is usually pneumatically or hydraulically operated.

A timer that controls the flow of the current and the exposure of the work piece to both the current and pressure. This timer is often used as a replacement for the human input.

A system that cools the electrodes when the current is switched off.

Not every configuration has all these components. In many cases, the cooling system is dispensed with if there is cooling time factored in the process. This cooling time is the period in which there is no electric current flowing and thus no heat generated because of resistance. The electrodes quickly channel the residual heat into the surrounding frame and in the air. Air-cooled electrodes are preferred because they remove the costs and expense of a dedicated liquid cooled system. However, this system becomes a necessity when the volume of the process demands quick operation of the system. To comply with the requirement, the cooing time is removed from the process. In order to compensate for this, a liquid cooled system is attached to the electrodes. This system removes the excess and residual heat from the electrodes.

Since application of pressures is an essential requirement of the process, the electrodes are often connected to a pneumatic or hydraulic system of clamps. In several designs, these clamps double as electrodes. However, since electrodes wear over overtime, because of constant exposure to heat and pressure, many design specifications treat electrodes and clams as separate components.