Spot welding is a process widely used across different industries to join metal parts together. The technique is considered as a type of resistance welding where we use electrical currents to generate heat enough to melt the metal to be bonded on other metal surfaces. A very popular way of welding in automotive and electronics industries where speed and efficiency is main importance. The spot welding process is very ideal for welding thin sheets of metal (commonly steel) and is very quick and cost-effective.
Brief history of Spot Welding
The spot welding process has been around since the early 20th century where the development of such techniques can be closely tied to the rise of the automobile industry. As cars became more common modes of transportation for the public, manufacturers needed to find a fast and reliable way to join metal parts. Over time, it has developed into the spot welding that we know today and is continuing to become more efficient and precise through the use of robotic spot welding and automatic welding machines.
Types of Spot Welding
The main goal of spot welding, like many other welding methods such as tig welding and mig welding, is to join metal parts, however there is no one-size-fits all process. Hence, there are many different types of spot welding found in the industry, each with its own different application and suited materials.
Resistance Spot Welding
The most common type of spot welding that you can find. It involves passing electrical currents through the metal sheets to create a weld at the point of content. The resistance spot welding is a process widely used in the automotive industry for joining steel panels, the quickest and most cost-efficient among all.
Projection Welding
The projection welding is a variation of spot welding where weld is localized to small projects on workpieces. You may imagine this method to be most suited for welding small parts like nuts and bolts to metal surfaces.
Seam Welding
Another method that is similar to spot welding but instead of fixed electrodes, it uses a rotating wheel to create a continuous weld. Ideally it is used to seal large metal containers like fuel tanks.
Flash Welding
A process where we heat metal surfaces with an electric arc and then pressing it together to form a weld. Commonly used for joining components such as metal rods and tubes.
Percussion Welding
This seemingly high-speed process is done by using high-voltage electrical discharges to melt the metal surfaces to then press it together quickly, which is more suitable for small and precise welds.
Advantages of Spot Welding
The reason for its popularity can be due to many reasons, the most prominent being the benefits it offers that makes it a preferred choice among different industries.
Efficiency in Mass Production
Spot welding stands out for its advantages of being very efficient to use especially in environments where mass production is done. It is very ideal for assembly lines where the process is quick and welds take just milliseconds for it to complete.
Strength and Durability of Welds
Despite the process being quick, the spot welds formed are incredibly strong and durable. When it is done correctly, it can create a bond that can withstand significant loads of stress and strain.
Cost Effectiveness
The speed of the process is not only the reason why spot welding is very cost-effective, it is also due to the relatively low energy consumption needed throughout the process as compared to other welding methods. It also does not require filler materials that most other welding methods need, which reduces the overall cost.
Automation Potential
In terms of automation, spot welding is one of the highly adaptable methods in this area, which is also why it is so popular in industries like automotive manufacturing. With that said, robotic spot welding has become a phenomenon in these industries as robots can now perform spot welds that are precise and consistent, helping businesses to improve production efficiency while reducing labor costs. This is also one of the main reasons that we at Hertztec are pushing new technologies and bringing in the latest spot welding machine in Malaysia to help the local industry keep up with changing times.
Conclusion
All-in-all, spot welding is a critical process in many industries that offers businesses a fast, efficient, yet cost-effective way to join metal parts. The versatility of this method combined with ongoing innovations like the latest robotic welding machines will ensure that it remains an integral part of manufacturing for years to come.
If you have any questions regarding spot welding or you would like to have experts to guide you on setting up a spot welding process for your business, feel free to reach out to us today.
