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June 07, 2021

Electric resistance welding is becoming a prominent and preferred choice among aviation welders. It is used to join thin metal sheets during the manufacturing process. Such items need high precision, and electric resistance welding can help achieve that. This blog post talks about electric resistance welding and its different types for aviation applications.

What Is Electric Resistance Welding?

Electric resistance welding is a precise process used to join metal parts together using an electric arc and pressure. It uses a strong electric arc to heat the metal and forge the melted parts. Resistance welding was invented in the 19th century, and since then, different types of welding procedures have been developed, such as plasma, laser, and electron beam.

How Does Electric Resistance Welding Work?

Electric resistance welding is a process ideal for joining thin metal sheets. This property makes it highly useful for aviation welding. The electric current is applied to the sheet through the electrodes that apply pressure to the sheets. This force is transformed to heat that welds the materials together. The electrode extracts the heat from the welded area and forms a nugget at the welding point, solidifying it.

Advantages Of Electric Resistance Welding

  • It is a quick process
  • Electric resistance welding can be used for large-scale manufacturing
  • It can join thin parts better
  • No flux or filler rod is required in this process
  • Some of the electric resistance processes are automatic and reduce the labor
  • There are no consumable materials used
  • The initial cost may be high, but it is a cheap process in the long run
  • It welds dissimilar metals together
  • Little skill is required to perform electric resistance welding

Types Of Electric Resistance Welding

There are different types of electric resistance welding, each having a unique application. The fives types of electric resistance welding are:

  • Seam Resistance Welding
  • Spot Resistance Welding
  • Projection Resistance Welding
  • Butt Resistance Welding
  • Flash Resistance Welding

Seam Welding

Seam welding uses two roller electrodes to join the overlapping metal sheets. The pressure remains constant, and a continuous joint is achieved through this method. Seam welding can be used to join the different types of metals together. This method is generally suitable for welding aluminum. Its applications are in automotive and aircraft. However, this method might make it difficult to weld parts thicker than 3 mm.

Spot Welding

Spot welding involves placing the sheet between the two electrodes, one is movable, and the other is fixed. The upward electrode puts out pressure that causes fusion. Heavy current is also passed through the electrodes. Spot welding is applied in the automotive, aircraft, and other related industries.

Projection Welding

Projection welding is a modified form of spot welding. It uses flat electrodes. The current is passed through them and the heat welds the materials required. This process is suitable for joining thicker parts. However, it is an expensive process.

Butt Welding

Butt welding also takes place across the entirety of the object rather than just on certain spots. A heavy current is required on the secondary side; therefore, more turns are on the primary side. The two parts are welded together, touching end to end. It is like joining two rods end to end. That's why butt welding is useful for welding pipes and rods.

Flash Welding

It is a welding procedure in which the parts themselves generate heat. The welder passes current through the joint that burns the surfaces irregularities. A thin film is also produced along the joint that gives the welding result you want. Flash welding can be applied to different types of metals and gives eminently perfect results. It is useful in welding railing ends, shaft axles and offers strength of up to 100%.

About Acorn Welding

Acorn welding is your most trusted welding company in Edmonton. Our qualified individuals are aware of the professional welding methods required for a safe aircraft welding experience. You can contact us for more information.