A spot welder uses an electric current to melt two pieces of metal together. It can be made with a power source, transformer, and electrodes, but commercial ones are more complex. It can join thin pieces of metal and thicker ones with protrusions. The correct width and duration are necessary for a strong bond.
A spot welder is a device that uses an electric current to melt two pieces of metal together. These typically work by using a transformer and large capacitor to create a large electric charge. Charge can then flow from one electrode of the spot welder, through the pieces of metal that are held together by the electrodes, and into the other electrode. The electrical resistance of the metal pieces can create a temperature high enough to weld them together. This creates a spot weld, which is literally a spot on each piece of metal that is welded to another.
The theory behind the spot welder, which directs current through pieces of metal, is relatively simple. Spot welding can actually also be achieved with a simple homemade device consisting of a power source, transformer and electrodes. However, commercial spot welders will tend to be more complex, with controls to change the amount of current and the duration of the weld. Some will also include a feature known as double pulse. This involves an initial pulse of current to soften the metals, after which the electrodes grip more tightly to achieve a stronger weld during a second pulse.
Spot welding is typically used to join relatively thin pieces of metal 0.02 to 0.12 inches (0.5 to 3 mm) thick. The amplitude of the current and the duration of the process can often be modulated, allowing a spot welder to join materials of different thicknesses and compositions. The correct width and duration will lead to a strong bond between the pieces, while either extreme will result in an unsatisfactory union. Too short a weld with too little heat and the bond will be weak, while too much heat can simply burn a hole through the metal pieces.
It may be possible to join thicker pieces of metal with a spot welder using a process known as projection welding. This variation of spot welding uses protrusions on the pieces being joined and involves directing heat to those specific points. This can allow thicker pieces to be joined without damaging the metal. It can also be used to weld things like bolts or other thick or unusual materials. At the ends, some spot welders may be able to weld materials as thin as 0.008 inch (0.2032 mm) or as thick as 1.25 inch (31.75 mm).
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