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Types of Resistance Element Welding with Examples

Introduction to Resistance Element Welding

Resistance element welding is referred to a combination of the welding process. These processes include spot and seam welding. Processes involved in resistant element welding produce coalescence. In the welding process, where the heat is uses to form, however, this is done with the help of the faying process. The material that has the electrical resistance the process is formed, that is combined with two things, which are time and the force that is necessary to use to hold the materials used in the process together(Bridigum, 2008).Resistant element welding is based upon the further development of the resistance that is conventional for spot welding process.

Types of Resistance Element Welding with Examples

Resistant element welding includes and combines both the mechanical and thermal principles for joining with the creation of the metal bond between the bottom plate and auxiliary elements of joining. The combination with force and form-locking connection is used in auxiliary joining elements with the top plate. Resistant element welding is a useful and convenient process to join the material. That is why it is widely used in the industrial settings and plants. There are three types of the resistant element welding. These types include;

  • Resistance spot welding
  • Resistance seam welding
  • Resistance projection welding

Seam Welding:

How does the seam weld work?

In the faying processes the welding has the two metals, which is known as a Resistance Seam Welding. However, the butt joint or an overlap, which is used in the seam welding, it should be noted that the process if automated. In the entire level of joint then, it is quite different as compared to the butt welding.

What is the seam welding?

Seam welding requires two types of electrodes and these electrodes are made from the copper. This is necessary for applying pressure and current. Thus, resistance Seam welding is an important component in welding the materials that are essential for joining.

How it works?

Seam welding transformer the supplies of energy in a well-oriented manner to the welding joint. This is done in the form of low level of current voltage as well as high level of current AC power voltage.It is to be noted that the joint of the work piece is an important component that has a high level of electrical resistance. This electric resistance is about the rest of the circuit in the welding process.

Moreover, the heating of its melting point by the current is evident in that regard. The semi-molten surfaces in the process are affectively pressed together( Davis, 2001).This is done by the welding pressure that is exerted which is responsible for creating a fusion bond. This fusion bond results in a uniformed manner and welded structure. It is also to be noted that most of the seam welders often uses water cooling. This is done through the electrodes in the process.


The major advantage of the seam welding is that it produces an extremely affective as well as durable welding. This is because the level of joint is forged. This happens due to the heat and its pressure that is applied accordingly( Jeffus, 2016).


The welded joint; is typically strong that is formed by the resistance, even then the material that is formed. This is transformer and controller that is assembled due to the heat generated in the process as a necessary element. The drawback of the seam welding is that it is the bit time consuming.

Which materials can be welded by Seam welding?

The major material weld in the seam welding is a different kind of metals. The metals include but not limited to iron, cast iron, and aluminum, copper, brass and alike.

Example of Seam Welding Machines:

 Types of Resistance Element Welding with Examples

Figure 1: Vertical type round seam welding machine

 Types of Resistance Element Welding with Examples

Figure 2: Automated MAG longitudinal seam welder

Projection Welding: 

What is the projection welding?

Projection resistance welding is developed with modification in spot welding. It is considered as the variation in the resistance welding process where the current flow is concentrated at contact services ( Phillips, 2016). This is done on embossed mechanized projection or cold heated. The projection affectively makes the current localized and forces the plates to get heated at mating the surfaces.

How it works?

With the projections and the raised section the welding process can be localized with the help. The work pieces that are needed to be jointed, the work is done on both the work pieces. In the welding process, in projections, the heat level is very concentrated. However, in the welding process in the process the close spacing and healthier section is permitted. It is to be noted that the projection is also used to position the work piece. The projection welding is, and affective method often used to weld the nuts, studs, screw machines and another part of heavy metals. The cross wires and bars are also welded through projection welding. This is considered as the high production process that depends on the multiple projections going to be weld and can be arranged by the suitable level of designing and jigging.


Projection welding has numerous advantages. This kind of welding is highly effective in welding large pieces of metals that are difficult to weld. Moreover, projection welding permits the process of welding for heavier sections. Moreover, it is to the closing spacing for the welding process that is quite affective and agile.


The positioning of the work piece is also necessary, and the projection is also used in such a manner that it positions the work piece. The major disadvantage is that it consumes lot of energy due to heavy metal welding work.

Which materials can be welded by projection welding?

The Martials weld by the projection welding includes metals of different kinds that include but not limited to cast iron, brass, and aluminum and alike. Heavy metal sheets are used to weld the plates. Therefore screw machines are also built through that process.

Example of projection welding machines:

Types of Resistance Element Welding with Examples

Figure 3: Stationary projection welding machine

Types of Resistance Element Welding with Examples

Figure 4: Rotating projection welding machine


            The present paper describes resistant element welding along with two of the types that include spot resistance welding and projection resistance welding. Both kinds of the welding are elaborated along with its advantages and disadvantages. The types of the welding machines and their functioning are also provided. Resistant element welding is considered as ta combination of the welding process. These combinations include spot as well as seam welding. Similarly, the resistance seam welding is another kind of a process that is also used for a welding. This use at the faying surfaces along with the two similar metals used in the process.

The major advantage of that welding is that it produces an extreme level of affective welding. The projection welding also has different advantages. This welding is very effective, and it is used for joining large pieces of metals for the sake of welding in an affective manner.However, the major disadvantage is its nature to consume lot of energy. This is apparently due to the heavy level of metal welding work.

  • Davis, J. (2001). Asm Specialty Handbook: Copper and Copper Alloys (ASM Specialty Handbook) (ASM Specialty Handbook). ASM International.
  • Jeffus, L. (2016). Welding: Principles and Applications. Cengage Learning.
  • Phillips, D. (2016). Welding Engineering: An Introduction. Wiley.
  • Bridigum, T. (2008). How To Weld (Motorbooks Workshop). Motorbooks.

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