Resistance Welding

Resistance Welding Process

Resistance welding is a metal joining process that utilizes applied pressure and electrical current. It involves passing an electric current with a welding electrode, which generates heat and melts the metal at the welding point. The metals are then pressed together, allowing them to bond as they cool down.

This method is used for high-speed production of spot welds in manufacturing. It’s essential to note that resistance welding is distinct from arc welding, which utilizes an electrical arc for heating and melting metals.

Geater’s Welding Capabilities

Geater is NADCAP Certified in resistance welding, using Weld Computer Technology to control a variety of weld parameters, for precise pressure and welding results.

We have the ability to weld aluminum and stainless-steel sheet metal materials to a sum total range up to .250” (1/4”) utilizing Military and AWS resistance welding specifications.

Welding Classifications A-B-C

There are three classifications or types of resistance welding, which are A, B, and C.

Class A

Class A material represents the highest group of electrode materials, with most common Cu-based alloys falling under this group. These materials have good strength and high electrical conductivity, making them suitable for welding various metals, including aluminum and other metals with good conductivity.

Class B

Class B material represents a group of high-strength alloys with reasonable electrical conductivity. These alloys are often used in applications that require high strength and strength-to-weight ratio, such as in the aerospace and automotive industries.

Class C

Class C material represents copper alloys with lower strength and electrical conductivity than Class A materials. These alloys are suitable for welding copper and copper alloys and are commonly used in the electronics industry.

Class A

Class A material represents the highest group of electrode materials, with most common Cu-based alloys falling under this group. These materials have good strength and high electrical conductivity, making them suitable for welding various metals, including aluminum and other metals with good conductivity.

Class B

Class B material represents a group of high-strength alloys with reasonable electrical conductivity. These alloys are often used in applications that require high strength and strength-to-weight ratio, such as in the aerospace and automotive industries.

Class C

Class C material represents copper alloys with lower strength and electrical conductivity than Class A materials. These alloys are suitable for welding copper and copper alloys and are commonly used in the electronics industry.

Amperage

Amperage ranges from 5,000 to 40,000 amps

Ranges of force utilized

200 lbs. to 700 lbs. of force

Geater has the capability to weld multiples of different assemblies within tight tolerance zones.

With a variety of different tooling, this enables our ability to be creative with different types of setup arrangements for a multitude of dissimilar assemblies.

Utilizing water coolers to increase weld time and longevity within the machines, as well as the tooling and the ability to produce more welds in a short amount of time.

Our Fabrication Capabilities and Processes

Resistance Welding offers several advantages, making it an efficient and cost-effective joining method for metals. Some of the benefits include:

With a short heating time and high concentration of heat, resistance welding is a quick and efficient process. It's ideal for high-volume production.

Unlike other welding processes, resistance welding doesn't require any filler materials. This reduces the overall manufacturing cost and eliminates the need for additional handling and storage.

The nature of the process allows for the molten metal to be isolated from the air, keeping the process simple and straightforward.

Unlike other welding methods, resistance welding does not produce sparks or fumes, providing a safer working environment for operators.

Resistance welding can join metals of various types, including dissimilar metals, and forms a weld that has a strong and durable bond.

By saving time, eliminating filler materials, and offering simplified metallurgical processes, resistance welding offers a significant cost advantage over other welding methods.

Due to the nature of the welding process, resistance welding works to ensure consistent and precise results, contributing to product quality and reliability.

Contact Us

Have a question or would like to talk with an expert about a project, call us at (319) 334-6026 or click here to contact us online!