Fundamentals of Small Parts Resistance Welding

This technical report outlines the principles and processes involved in resistance welding, a thermo-electric method used to join parts by generating heat at their interface through electrical current. The report details the advantages of resistance welding, including its short process time, operator safety, and environmental friendliness. It explains the significance of bulk and contact resistance in the heat generation process, emphasizing how the surface conditions of the materials influence the effectiveness of the weld. The document further describes the heat balance during welding and the types of bonds formed, such as solid state, fusion, and reflow braze bonds. Additionally, it discusses the impact of material properties, including electrical resistivity, thermal conductivity, and hardness, on the welding process. The report concludes by addressing potential issues such as oxide contamination and surface roughness that can affect weld quality, providing insights into best practices for achieving reliable welds.