The amount of current used, weld time and electrode force pillars of successful welds form the basis of these tips from experts. Resistance welding in its simplest form: As two sheets of mild steel are pressed under a controlled force by copper-alloy electrodes, a controlled and timed electric current passes through the two sheets. As the highest circuit resistance occurs at the sheets' point of contact, this is where the weld current generates heat and causes a weld nugget to grow. After the current stops, with the sheets held under pressure, the molten material from the two pieces flow together and solidify to form a weld. The term resistance welding owes to the fact that the electrical property of resistance of the metal being welded causes heat generation as current flows through it.
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