Design of Spot Welding Joint
Spot welds are a type of weld where a pair of overlapping metal parts are unified by localized heat and pressure. Although very small in size, this type of welding joint offers great strength which is why it has been the primary way to join overlapping sheet metals for the past century.
Spot welds do require special equipment and a higher understanding of the welding process in order to be done properly. When done correctly, it provides superior strength and a clean look. In order to make a spot weld, there must be two joined surfaces and the corresponding spot welding tip on the welder itself.
The weld size and shape can vary depending on the desired outcome. A small, round spot weld will provide just enough weld joint to keep two overlapping sheets of metal together. Although very small in size, this type of small spot weld provides good strength. A larger, rectangular spot weld also provides good strength and a more aesthetic look.
Spot welding also requires correctly adjusted jigs and fixtures that must match the sheet metal thickness. These jigs and fixtures will provide the right amount of pressure and the right amount of heat at the same time, which allows the two pieces of metal to come together and form the desired weld joint. Therefore, if the jigs and fixtures used to hold the two pieces of metal together need to be adjusted, they must be adjusted accordingly.
The correct welding parameters must be set in order to ensure that the desired weld joint is achieved. The welding current must be exactly what the welding process requires in order to form the weld joint effectively. This current will depend on the type of metals being used, the required spot weld joint size, and the type of electrodes being used.
The weld size should also have specified dimensions. For example, the weld size should never be too large or too small. Too small of a weld size can reduce the strength of the weld joint, and too large of a weld size may result in unacceptable amounts of unmelted metal in the weld joint.
Additionally, the electrode shapes must be chosen according to the particular weld joint being formed. Various shapes of electrodes are available, and the correct shape should be chosen depending on the particular joint being formed. For example, a round-edged electrode may be best suited for a small, round weld joint. Whereas an arc-shaped electrode may be best suited for joining two overlapping sheets of metal.
The welding gun must be set at the correct voltage and amperage so that the correct weld joint is achieved. The correct welding power must also be specified to ensure that the weld joint is formed correctly. Additionally, the welder should ensure that the drive rollers of the welding gun are in proper alignment with the metal pieces being welded, as misalignments may result in poor weld joint quality.
Spot welding, when done correctly and with the right tools, can provide a good, strong weld joint. It’s a reliable and relatively simple welding process that can be used to join overlapping sheet metals. Although specialized knowledge and tools are required, using spot welding will ensure that the weld joint looks neat and clean and is strong enough to last.
