In Resistance welding

The process of joining two pieces can be done using several methods, one of the most popular being resistance welding. This process is commonly used in different types of industries, especially for mass production, since resistance welding is a fast and reliable method.

Resistance welding is a thermoelectric process through which two pieces are pressed together by means of electrodes provided by a welding machine. The heat produced by means of the electrical current during a time and with a controlled tension manages to melt the material, and the pressure makes the pieces melt permanently.

There are three aspects that directly influence the resistance welding process, so they should be taken into account when making an optimal weld: the time used, the material, and the welding power.

At Bearcat we supply and implement state-of-the-art resistance welding technology, as well as other technologies focused on sheet metal workshops in the automotive industry. Let’s see what are the basic types of resistance welding that exist. As well as other peculiarities of this process so used in the industry.


 There are three basic types of resistance welding that exist:

  • Electric spot welding: It is used to join two metal pieces through points by applying pressure on the pieces to be joined with the electrodes. At the same time, the current is allowed to pass until the junction point melts slightly; it is allowed to melt and a regularly spaced spot weld is obtained. This welding system is applied to any type of sheet metal, especially in the mass production of automobiles.
  • Seam welding is very similar to electric. The only thing that differentiates them is that in seam welding the electrodes incorporate rollers at the tip that rotate on the plates to be welded, exerting pressure to achieve a smooth and uniform joint. This type of seam welding is often used in the manufacture of steel tubes, as well as in the creation of beverage cans of this same material.>
  • Resistance butt welding: this system joins the edges of the parts to be welded one next to the other, held by fasteners connected to the secondary winding of a transformer that controls the electric current.



Resistance welding has many more advantages than disadvantages. One of its main advantages is that it favors the production volume, since it is a very fast welding method, perfect for mass production lines.

At the same time, it is a safe system since the energy it uses is low voltage, which entails a low risk at work level.

On the other hand, resistance welding results in a reliable joint through an ecological and clean process. In fact, it does not require consumables or other materials to be able to apply this welding process beyond what is described in its operation.

Even so, like almost all methodologies, it can be influenced by some by a couple of factors. One of them is that to apply resistance welding it is necessary to have an equipment with high initial costs. It should also be noted that the weld joints that can be made are only lap joints for most resistance welding processes.



At Bearcat we have had strategic partners in the automotive sector for more than 40 years, such as NIMAK, BRÄUER, IVOSTUD or VBS, which allow us to offer innovative solutions aimed at industrial joining techniques.

For example, NIMAK develops and produces robots and manual welding guns and welding machines. At BRÄUER, they are automotive experts, offering customized solutions for both electrode processing and automation of welding processes.

VSB is another German company with extensive experience in joining techniques in the automotive sector. While IVOSTUD offers innovative solutions in automated bolt welding systems for the transportation industry.

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