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WE702 Resistance Welding: Materials Considerations

This is the second course in this series (WE602 & WE702).† It will concentrate on the materials interactions and changes in properties that accompany resistance welding of parts.† The previous course (WE602) concentrated on the process and control of that process.† As a new welding engineer you might be asked to resistance weld on some material which your company has never used before, perhaps stainless steel or nickel alloys.† How will a resistance weld on this new material effect its properties?† What welding procedure will you select?† If you select wrong, what is liable to happen?† Letís talk about these things together in this course.



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Catalog description:  The fundamentals of resistance welding with emphasis on process analysis and metallurgical aspects of weldability.

Prerequisites: WE601

Required Materials: Resistance Welding Lecture Notes

Schedule: SP Qtr., 3 classes/week


Overview of Resistance Welding (1 week)

Weldability of Uncoated Steels (1 week)

Weldability of Coated Steels (2 weeks)

Weldability of Hardenable & Stainless Steels (1 week)

Resistance Welding Aluminum Sheet (1 weeks)

Resistance Welding of Copper, Nickel and Cobalt Alloys (1 week)

Resistance Weldability of Titanium and Refractory Alloys (1 week)

Resistance Weldability of Magnesium and Zinc Alloys (1 week)

Resistance Welding of Composite and Clad Materials (1 week)


Contribution to Professional Component (Criterion 4) of ABET 2000:

            a)            Mathematics and Basic Science            0 Credits

            b)            Engineering                                           3 Credits

            c)            General Education                                 0 Credits

Relationship of Course to Program Objectives:

1B        Apply the fundamental principles of science to analysis of physical phenomena

2A            Describe the basic operating theory of the various materials joining processes including arc, resistance, solid-state, and high energy density welding

2C            Understand materials principles and how materials are influences by joining processes.

3A            Establish welding procedures to guide production and welding personnel relative to specifications, materials, processes, design and testing.

Course Objective: Students will develop an understanding of the weldability of various material alloy systems that are commonly used in commercial resistance welding manufacturing.  An understanding of the inter-relation between process selection, power supplies, and metallurgical variables will be obtained.

Learning Outcomes:  Students should be able to:

1.      Understand the similarities and differences between the various resistance welding processes and their effect on production of metallurgically sound welds

2.      Understand the relationship between materials and spot weldability for a large variety of alloy systems

3.      Use the concept of resistance weldability to develop welding procedures in various industries including the automotive, appliance, electronic and aerospace applications

4.      Trouble shoot welding defects which occur as a result of the various process and materials variables in the system

5.      Understand how material coatings effect weldability


Course Lectures


Processes Review

Uncoated Plain Carbon Steels Steel Production
Uncoated Plain Carbon Steel Process Variables
Uncoated Plain Carbon Steel Process Variables 2
Uncoated Plain Carbon Steel Material Variables
Flash/Butt Welding Plain Carbon Steel
Coated Steel Production
Coated Steel Weldability
Nugget Development of Uncoated Steel
Zinc Painted Steels
Zinc Aluminum Alloy Coated Steel
Aluminum Coated Steel
Tin & Terne Coated Steel
Hardenable Steels
Aluminum Coated Stainless Steels
Stainless Steel
Stainless Steel 2
Stainless Steel 3
Aluminum Production and Properties
Aluminum Spot Welding
Spot Weld Al Equipment
Other Aluminum Welding Processes
Clad Aluminum
Inspection and Testing
Cobalt Based Alloys
Nickel Base Alloys
Reactive, Refractory, and Precious Metals & Alloys
Composite Materials
Clad Materials
CQ, DQ & IF Steels
Dual Phase Steels
HAZ Structure Property Changes
HSLA Steels
Rephosphorized Steels
Resistance Welding of Cold Rolled Sheet
Resistance Welding of Hot Rolled Sheet
TRIP Steels

Instructor Info

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David W. Dickinson


Phone: (614) 292-0801

Link to Bio-Sketch

Teaching and Research Interests:

Resistance Welding, Welding Metallurgy, Welding Project Management, Welding Production, Sensing and Control of Welding Processes, Welding Fume and Noise Studies, Educational Technology Development, Continuous Quality in Manufacturing and Educational Environments


Rensselaer Polytechnic Institute Troy, New York

B.S. Materials Engineering, 1967

Ph.D. Materials Engineering, 1972

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Last edit: 03/10/2003

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