Resistance / Spot Welding Applications

Download the entire Welding Products Catalog (PDF 30MB)

Resistance (or spot) welding is the most cost-effective process for joining both similar and dissimilar metals. It also lends itself very well to automation. Because of these characteristics, resistance welding is used in the following welding applications:

Click on the links below to learn more about our resistance / spot welding applications.

Flash
Projection
Spot
Seam
Cross-Wire
Upset
Resistance Brazing

Technical Information

CMW's resistance welding products serve a wide range of industries including Automobile & Transportation, Defense, Electronics & Telecommunication, Construction/Building Products, Consumer Goods, Marine Products, Recreation, Farm & Construction Equipment, Energy, and more.

CMW's resistance / spot welding materials include CMW®28, CMW®3, CMW®328, CMW®73, CMW®353, CMW®100, Elkaloy® D, Elkaloy® 20, our Elkonite® Copper Tungsten family, Elkon® 100W Tungsten, and Elkon® 100M Molybdenum.

Flash: Two parts to be joined are clamped in dies (electrodes) connected to the secondary of the resistance welding transformer. Voltage is applied as one part is advanced slowly towards the other. When contact occurs resistance heating occurs. High current density causes rapid melting at the point of contact. This action is called flashing. CMW can make dies (electrodes) to customer specifications.

Projection: Projection welding is a resistance process by which the current & heating during welding are localized at a predetermined point by the design of the parts being welded. This is usually accomplished by a projection, or embossment, on one or both of the work pieces. CMW offers Chameleon/Max-Life® Nut welding electrodes, Self-Piloting Nut welding electrodes, Non-Piloting Nut welding electrodes, Chameleon/Max-Life® Stud welding electrodes, Stud welding electrodes and Back Up electrodes.

Spot: Resistance spot welding is made by passing current, for a timed interval, through the workpieces from electrodes which apply the welding force. CMW offers consumables in the form of caps which are used with shanks and are used with varying holders. CMW also offers straight electrodes, single bend electrodes, double bend electrodes and various other type of bent & or flattened electrodes which fit directly into the previously mentioned holders.

Seam: Seam welding consists of making a series of overlapping spot welds by using one or two rotating wheel electrodes without opening the electrodes between spots. CMW offers to make any wheel to the customers specifications.

Cross Wire: In practice, it usually consists of welding a number a parallel wires at right angles to one or more wires or rods. CMW offers both Elkonite® Faced & Elkon® faced electrodes.

Upset: Is a resistance welding process which produces coalescence simultaneously over the entire area of abutting surfaces or progressively along a joint.

Resistance Brazing: Resistance brazing is a method of low temperature brazing by the application of heat and force to the parts to be joined using heat generated by the current in either the parts themselves, in the dies holding the parts or the electrodes making contact with the area to be brazed, or both.

Technical Information

The links below will give you access to additional data that can assist you in understanding what is needed for certain applications, maintenance and set-ups. Please feel free to review and print for your convenience.

Application Data Sheet
Electrode Maintenance
Application Sheet for Typical Multiple Spot Welding Set-Ups
Typical Set-Up Combination