Mechanical Basics

What Is Resistance Welding?

Resistance Welding is a type of metal joining process (or type of welding) that uses pressure and electrical resistance to weld (or join) the two thin metal pieces. This type of welding process works purely on electricity. The Resistance Weld does not require any joining or filler metals and even the arc is not developed during the welding process. In some cases, the resistance weld uses hydraulic pressures (or manual) in the joining process.

Resistance Welding, Types Of Resistance Welding, Its Advantages And Applications

The current supplied to the resistance weld will be converted to heat energy (or thermal energy) and it will flow through the electrodes of the welding. The sheet metals that are to be joined will feed into the two electrodes and due to this contact; the sheet metals will be welded (or joined). The amount of heat generated (or required) in the resistance welding process can be given as

Resistance Welding, Types Of Resistance Welding, Its Advantages And Applications

  • H – Amount of Heat Generated
  • I – Current Flow (in Amperes)
  • R- Resistance (in ohms)
  • T = time for current flow (in seconds)

What can you learn from this post?

  • Types of Resistance Welding
  • How Does Resistance Welding Works?
  • Advantages of Resistance Welding
  • Applications of Resistance Welding
  • Conclusion

Types of resistance welding:

There are different types of resistance welding according to their way of welding the metals, and their usage of parts. 

These are the types that we can see in industries or some other places. You can read about these types in detail in upcoming posts.

How Does Resistance Welding Works?

 It is mainly used to join the thin metal sheets. Therefore, the Electrical Electrode will be one of the common parts in each type of welding. The two thin metal sheet that required to weld is placed between two electrodes and force is applied on them. The heat is developed due to the current passage once the tip of the electrode touches the metal sheet. Further, the pressure and heat of the electrode melts the sheet metal, and solidifying the metals will result in joining.

Due to the pressure and electricity, a weld nugget is formed spot where the electrodes are pressed forcefully. This is a sign of welding accomplished.

Advantages of resistance welding:

The advantages of this type of welding are very notable and unique when compared to the other types of welding. The advantages of resistance weld will be varying according to the resistance weld type. The few and main advantages are

  • The resistance weld process can join the thin sheet materials without using any arc.
  • The usage of electricity and easy operation is another main advantage.
  • The construction s is easy.
  • No gas or filler materials are required to perform the operations.
  • The main advantages of resistance welding are that the operation is faster and quicker when compared to other types of welding.
  • This type of welding can be used to join the dissimilar metals 
  • The heat developed in this type of welding does not lead to any life-risk accidents.

Applications of resistance welding:

The applications of resistance welding are

  • This type of welding mostly observe in the Automobile Industries to join the thin sheets.
  • The boiler sheets and leak-proof materials will be welded with this type of resistance weld process which is a unique.
  • Resistance weld process is used in large production industries.
  • The applications of this type of welding process are frequently found in pipe joining Industries or workshops.


Resistance Welding and its types are totally different and unique to the other types of welding like arc welding, and gas welding. If we observe, all types of resistance welding will not produce any arc and gas in its joining process. Due to the production of only heat, it can be chosen for large productions and high field applications. The parts are simple and do not contain any heavily weighted devices.

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