Resistance Welding

Advantages

Suitable for welding dissimilar metals
Capability of multiple welding
High volume work at high speeds
Short (millisecond) weld times
Quality of process monitoring
Low voltage safe process without fumes
Readily automated, versatile process
Suitable for welding multiple thicknesses – “thin to thick”
Unskilled operators – welding process is fully automated
Clean welding process without gas, filler wire or fluxes
Highly industrialised and well proven process
Many components can be resistance welded without any design changes
Efficient energy use

Processes
Products
Applications
Industries

What is Resistance Welding?

Resistance welding is the science of joining two or more metal parts together in a localised area by the application of heat and pressure.

The heat is produced by the resistance of the material to carry a high amperage current.

The greater the path of resistance is, the higher the heat intensity.
This heat is controlled via time application and level of current applied.

The pressure is applied to forge the joint and consolidate the nugget to provide the weld strength.

No extraneous materials such as rods, fluxes,
inert gasses, oxygen, or acetylene are required.

Battery Tab Welding

Resistance welding in parallel passes the current between the two top electrodes, which flow through from one side of the battery terminal to the other side of the same terminal. No current flows through the battery cells.

battery tab process

Heat affected zones are created at the boundary where the tab rests on the battery due to the dimples on the tab. The heat generated due to the electrical resistance creates the weld at each point. Due to having 2 heat affected zones the transformer uses a higher secondary voltage (7.8V) to achieve a strong weld.

FW2

Single upper electrode and single lower electrode.
Manual foot pedal / cable operation.
Supports up to 3KVA Further information

FW2/P

As FW2 but with pneumatic operation.
Supports up to 3KVA Further information

FW2/P

FW2/T

As FW2 but with twin upper electrodes.
Manual foot pedal / cable operation.
Can be used in series (as per FW2) or in parallel.
Supports up to 3KVA Further information

FW2/T/P

As FW2/T but with pneumatic operation.
Supports up to 3KVA Further information

FW2/T/BW

As FW2/T but designed with adjustable post suitable for battery tab welding.
Supports up to 3KVA Further information

FW2/T/P/BW

As FW2/T/BW but with pneumatic operation
Supports up to 3KVA Further information

FW2/T/P/BW