Metal fabricators always ensure the processes used for stainless steel fabrication, aluminium fabrication or steel fabrication are cost-efficient. Whether it is laser cutting, metal bending, welding or metal rolling, they must comply with the safety code and increase cost-efficiency for the metal fabrication shops.

This is the reason why Spot Welding or Resistance Welding (RW) have a long-lasting run in the metal fabrication industry. However, after so many years, people still don’t realize the potential of RW. It has so much more to offer than just regular sheet metal joins.

Let me tell you about some of the more unusual uses of Spot welding.

Resistance Welding (RW) Annealing

Even though sending the parts through an annealing over can seem like an economical decision, it certainly lead to unwanted distortion. Apart from that, when the production volume is limited, oven annealing is perhaps not the best solution.

A good way is to pass an electric current through its joint. The Resistant Welding control utilizes an integrated infrared temperature feedback device. Then the fiber optic lens measures the temperature which is shown in a lead-in photo. This way, metal fabricators can achieve a controlled temperature rise-&-hold curvature to anneal the joints without forcefully altering the geometry or metallurgy of the part.

Cross-Wire Welding

Most fabricators think RW to be merely a process to join any round wires for making dishwasher racks or store displays. However, this cross wire welding can certainly be used for other components like filaments of light bulbs, bread toasters, to even automotive seating.

Fusing the Stranded Wires

Spot welding or Resistance welding can be used to safely fuse the cut ends or the flat wire cables. Fusing the stranded wire ends could replace the crimp connectors that will increase reliability and reduce production cost.

Dissimilar metals joint using Percussion Welding

Resistance welding is used to join dissimilar metals like components used in the switch gears that are consists of 2 silver contacts which is joined to the solid copper bar.

This Percussion welding takes the help of specialized resistance welding machines that create high-temperature arcs between metal parts. Then it rapidly forges the metal parts together.

Joining the nails

The resistance welding process is often used to join rolls of small to large nails that are used in the pneumatic nail gun magazines. The secret to this process is synchronization between the welding control and nail feed.

Hot Upsetting

This hot upsetting is generally used in the production of different metal parts. Using Resistance or Spot welding process for heating metal rod end before forcing it into the die can help you achieve any shape with maximum precision.

For Hardened Metal

Joining the spring steel and heat treated metal can be challenging. The temperature obtained by RW is usually the same as the temperature in heat treating.

Trying to cool the welding nuggets fast can lead to brittle joints. However, the advanced welding controls let annealing and welding to be done in one-single process.