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Resistance Spot Welding

Resistance Spot Welding


  • A Land Rover has around 4500 spot welds


The Process

Resistance spot welding (RSW) is the most widely used welding technique for the manufacture of steel body-in-white assemblies. It joins materials in a localised area using a combination of heat and pressure. Two electrodes apply pressure to the joint while at the same time passing an electric current through it to establish the join.

The PVLT team at WMG has developed a tool to clean the electrode heads at regular intervals to increase the life-span of the electrodes specifically for application on aluminium joints. Without the ‘Gyro-buffer’ and associated process control, the RSW of aluminium process has proven incapable of delivering the required quality levels for volume production; with buffering, the electrodes have proven capable of circa 10,000 welds per electrode in industrial line trials.


Resistance Spot Welding diagram


The Benefits

  • Reliable and established technology
  • Requires low skill level to operate
  • Readily automated and high speed
  • Relatively inexpensive compared to alternative methods
  • Flexible application – 1 tool can approach multiple material stacks
  • Minimal distortion