There are several processes that are often carried out for steel and other metal products, and one of the most common is welding. There are numerous different types of welding out there, and one that’s used across a few different major industries is known as spot welding.

At Wasatch Steel, we’re happy to offer a wide range of steel products and steel services for clients around Salt Lake City and other parts of Utah. What is spot welding, what are its benefits and limitations, and which applications are most common using it? Here are some basics.

What is Spot Welding?

Spot welding is actually just one type of an entire sub-category of metal welding, one that’s known broadly as resistance welding. Various resistance welding formats, which also include those like flash welding, seam welding and projection welding, all focus on using heat from electrical resistance to join two metals together.

In spot welding, the process uses a pair of electrically charged copper electrodes that create an intense heat when they come in contact with each other. This forms a bond between the surfaces, with the metal acting as a conductor to build up the heat.

From he, firm pressure will be applied to both sides of the metals, joining them together. The current maintains a constant heat and pressure, joining both sides together. The duration of the current is determined by the kind of metal fusion that’s desired.

Key Benefits of Spot Welding

There are a few reasons why spot welding is especially beneficial in many settings:

• Simplicity: This process is actually quite simple. It’s also something that can be automated with relative ease, making it even more efficient in many production settings. It requires no complicated procedures, no fluxes and no special skills.
• Speed: The welding process is also very fast, with the joint being produced in a matter of seconds. This makes it especially useful for high volume production operations.
• Ease of automation: As we noted above, spot welding can be automated very easily, taking the human element out of the equation and allowing for more consistent results. This also makes it easier to keep production costs down as well.
• Multi-sheet welding: In cases where multiple sheets of metal need to be joined, spot welding can make that process much faster and more efficient.

Limitations of Spot Welding

Of course, there are also some limitations to consider when it comes to this type of welding:

• Not an overly strong bond: Because this welding type only uses an electrical current, the bonded area will be small and local. As a result, it’s not as strong of a bond as more traditional welding types.
• Not suitable for all metals: Spot welding also won’t work with some metal materials, mainly those where a current cannot be passed through.
• Possible warping: In some cases, spot welding may cause warping or distortion to the metal due to its intense heat.

Applications of Spot Welding

Overall, spot welding is used in a wide variety of industries and applications. These include:

• Automotive: As one would expect, this type of welding is quite common in automotive repair, maintenance and production settings.
• Aerospace: Spot welding is also used in the production and repair of aircraft, as well as other related components.
• Electronics: It’s also used frequently in the manufacture of electronic devices, particularly those that involve metal components.
• Medical: The medical industry often uses spot welding for various implants and prosthetics. For instance, dental implants are often spot-welded prior to being placed in the patient’s mouth.
• Fabrication and repair: Finally, spot welding is frequently used in metal fabrication and repair settings. This includes the repairs of pipelines, tanks, boilers and more.

Best Practices for Spot Welding

If you’re going to be utilizing spot welding for steel or any metal, here are some simple areas to ensure you’ve considered:

• Time: The length of time for spot welding will depend on the thickness of the metal and other factors. It’s important to set a timer when you start welding, so as to make sure that you don’t overheat or burn the metal.
• Current and force: Ensuring you have the proper settings for the current and force is essential. Too much of either can damage the metals, while not enough won’t create a strong bond.
• Cleanliness: It’s also important to make sure that all of your tools are clean and free of any oil or dirt that could cause problems during welding.
• Safety: Finally, it’s absolutely essential to take proper safety precautions when spot welding. This includes wearing protective gear, ensuring ventilation and not allowing anyone who’s untrained in the process near the equipment.

Spot welding is a common metalworking technique used across many industries. It offers many advantages with regards to speed and ease of automation, but there are some limitations that should be taken into consideration. By following the best practices for spot welding, you can ensure that your projects are completed safely and efficiently.

For more here, or to learn about any of our metal or steel products for SLC clients, speak to our team at Wasatch Steel today.