Resistance Spot welding

Resistance spot welding is a thermo-electric process where heat is generated at the interface of the parts to be welded by passing an electrical current through them for a precisely controlled time and under force. The “resistance” in the name resistance spot welding comes from the fact that the resistance of the workpieces and electrodes are used in combination or contrast to generate heat at their interface.

Following are some of the thousands of photos and video examples of resistance spot welding applications that have come through our applications labs.

Resistance Spot welding

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    Power Supply | Alt. Power Supply
    IPB-5000A-MU
    Weld Head or Focus Head
    TL-088B-EZ
    Weld Monitor
    MG3
    Material(s)
    Copper
    Method
    Resistance Welding
    Industry
    Battery
    End Product
    Battery Pack
    Other Features
    Integrated: MG3, Bar Code Reader and Polarity Sensor

    Resistance Welding – Battery Welding System

  • Resistance Welding Stainless Steel Cap Nail - battery welding, steel, nickel, brass, tin, spot weld, 180A, HF2, resistance weld
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    Power Supply | Alt. Power Supply
    HF2
    Weld Head or Focus Head
    TL-180B-EZ
    Material(s)
    Cap: Nickel Coated Steel | Nail: Tin Coated Brass
    Dimension(s)
    Cap: 0.12-0.14" | Nail: 0.94" dia
    Method
    Resistance Welding
    End Product
    Battery

    Resistance Welding Stainless Steel Battery Cap to Nail

  • Battery Cap- Nickel - Resistance Welding, UB29, UB29A, 88A/EZ, Batteries, Welding Spot, Nickel, Battery, Battery Packstabs, caps, parallel gap
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    Application Details

    Power Supply | Alt. Power Supply
    UB-500A | UB-1500A
    Weld Head or Focus Head
    TL-088B-EZ
    Material(s)
    Nickel
    Method
    Resistance Spot Welding
    Industry
    Batteries
    End Product
    Battery, Battery Packs

    Battery Cap Spot Weld

  • Solar - Ribbon to Resistor Lead - Resistance Welding - Copper with Tin Plating - Resistance Welding, IS-120B, 180A/EZ, Electronic Components, Energy Welding Spot, Copper, Tin, Plating, Solar Weld, ribbon to resistor lead
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    Application Details

    Power Supply | Alt. Power Supply
    IS-300CA
    Weld Head or Focus Head
    TL-180B-EZ
    Material(s)
    Tin Plated Copper Ribbon
    Method
    Welding, Spot
    Industry
    Electronic Components, Energy
    End Product
    Solar Panels

    Ribbon to Resistor Lead Welding

  • Cable Terminal - Resistance Welding - Cold Rolled Steel & Copper - Resistance Welding, HF2, F120-Z, Electronic Components, Resistance Welding, Cold Rolled Steel, Copper cable terminal
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    Application Details

    Power Supply | Alt. Power Supply
    HF2
    Weld Head or Focus Head
    F120-Z
    Material(s)
    Cold Rolled Steel | Copper
    Method
    Resistance Welding
    Industry
    Electronic Components
    End Product
    Terminal Cable

    Cable Terminal Connection

  • Motor - Resistance Welding - Silver Strip to Square Copper Flange , "Resistance Welding,IPB-5000A-MU, 89A/EZAutomation Electronic Components, Resistance Welding, Copper, Silver, Motor Weld, silver strip, to square flange"
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    Application Details

    Power Supply | Alt. Power Supply
    IPB-5000A-MU
    Weld Head or Focus Head
    TL-180B-EZ
    Material(s)
    Silver Strip | square Copper Flange
    Method
    Resistance Welding
    Industry
    Electronic Components
    End Product
    Motor

    Motor - Hair Pin Welding

  • Roll Spot Seam Weld Strip -Resistance Welding - Copper to Steel, Resistance Welding, STA-100A, Roll Spot, Telecom & DisplayWelding, Seam Copper, Steelseam weld, with no undercut, or blowout Tape Strip
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    Power Supply | Alt. Power Supply
    ST-100A or UB-1500A
    Weld Head or Focus Head
    Roll Spot
    Material(s)
    Copper | Steel
    Method
    Roller Spot Welding
    Industry
    Telecom & Displays

    Roll Spot Seam Weld

  • Sensor - Resistance Welding - Resistance Welding, Motors & Coils Welding, Spot , Resistance Welding Sensor
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    Application Details

    Power Supply | Alt. Power Supply
    HF2
    Weld Head or Focus Head
    SL-301A
    Material(s)
    Copper | Tin Plated Phosphor Bronze
    Dimension(s)
    25 AWG | 1 mm
    Method
    Resistance Welding
    Industry
    Motor & Coils
    End Product
    Sensor

    Sensor - Resistance Welding

  • Solenoid Wrapped insulated wire to terminals - Resistance Welding - Copper Phosphorous bronze - Resistance Welding, HF2, 180A/EZ, Electronic Components, Motors & Coils, Welding Spot, Resistance Welding, Bronze Copper, CU Phosphorous bronze, Solenoid, Weld Wrapped insulated, wire to terminals
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    Application Details

    Power Supply | Alt. Power Supply
    HF2
    Weld Head or Focus Head
    TL-180B-EZ
    Material(s)
    Bronze Copper
    Method
    Resistance Welding
    Industry
    Electronic Components
    End Product
    Solenoid
    Other Details
    Welding of wrapped insulated wire to terminals

    Resistance Welding -Wire to Terminals

  • Triple Layer - Resistance Welding - 1074 Steel - Resistance Welding, IS-120B, IS-300CR, 180A/EZ, MM-370A, MM-380A, Automotive Contract, Manufacturer Sheet, Metal Welding, Spot 1074 Steel, 3 layer, Triple Layer
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    Application Details

    Power Supply | Alt. Power Supply
    IS-300CA
    Weld Head or Focus Head
    TL-180B-EZ
    Material(s)
    1074 Steel
    Method
    Resistance Welding
    Industry
    Automotive

    Resistance Welding - Triple layer steel

  • Truck Air Springs Spud Fitting Case - Resistance Welding - Steel 1012 Mild - Resistance Welding, IS-300CR, C-Frame, Automotive Contract, Manufacturer Sheet, Meta lWelding, Projection Welding, Spot Steel Steel, 1012 Mild Steel, 1020 Mild, Air Springs, Weld Truck Air Springs, Spud Fitting case
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    Application Details

    Power Supply | Alt. Power Supply
    IS-300CA
    Weld Head or Focus Head
    C-Frame
    Material(s)
    Steel, Steel 1012 Mild, Steel 1020 Mild
    Method
    Welding, Projection, Welding, Spot
    Industry
    Automotive, Contract Manufacturer, Sheet Metal
    End Product
    Air Springs

    Resistance Welding - Spud Fitting Case

  • Gas Tank Tube Bracket - Resistance Welding - Projection 1012 Mild Steel, Resistance Welding, IS-300CR, ISA500CR, MH-1401, Automotive Contract, Manufacturer Sheet, Metal Welding, Projection Welding, Spot, Steel, Steel, 1012 Mild Steel, 1020 Mild, Gas Tank Tube, Bracket
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    Application Details

    Power Supply | Alt. Power Supply
    IS-300CA
    Weld Head or Focus Head
    MH-1401
    Material(s)
    1020 to 1012 Mild Steel
    Method
    Resistance Welding
    Industry
    Automotive
    End Product
    Gas Tank Tube Bracket

    Resistance Welding Tube Bracket

  • Coil welding

  • Wire to terminal

  • Sensor

  • Sensor

  • Sensor

  • Honeycomb

  • Fuel Pump Assembly

  • Switch assembly

  • Fuel pump housing

  • Relay assembly

  • Wire harness

  • Automotive Capacitor

  • Automotive sensor

  • Fuel Pump Assembly

  • Fuel Pump Assembly

  • Fuel Pump Assembly

  • Motor Armature

  • Air bag cylinder

  • Wire mesh

  • stainless steel medical electrode - medical, stainless steel, medical electrodes, spot welding, inverter, HF27, 80F
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    Power Supply | Possible Alternative
    HF-2700A, HF-2599A
    Weld Head
    TL-080B-F
    Method
    Spot Welding
    Material(s)
    Stainless Steel
    Dimension(s)
    Thickness - Tube: 0.002" | Housing: 0.125"
    Product End Use
    Medical Probe
    Other
    N/A

    Medical Probe - Tube to Housing Weld

  • Magnet Wire Medical Electrodes

  • Catheter

  • Hypodermic drug delivery

  • Guidewire

  • Guidewire

  • Electronics: cold rolled steel

  • Electronics: wire to terminal

  • stainless steel tweezer - medical, stainless steel, tweezer, resistance welding, inverter, IPB5000, 180A/EZ
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    Method
    Resistance Welding
    Power Supply
    IPB-5000A-MU
    Weld Head
    TL-180B-EZ
    Material
    Stainless Steel and Titanium
    End Product
    Tweezers

    Tweezer

  • Medical electrode

  • Medical tool

  • Tab to coin cell

  • Copper magnet wire

  • Nickel plated steel battery terminal welding

  • Battery tab welding nickel

  • Nickel and cold rolled steel battery tab welding

  • Nickel plated steel battery tab welding

  • Tab to terminal welding - nickel and silver plated copper

  • Battery welding Ni - CRS

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