Mar 7, 2023 11:30:00 AM | Written by AMPCO METAL

Resistance welding is a popular method in the automotive industry, thanks to its speed, consistency, accuracy, and cost-effectiveness. To enhance performance in this sector, AMPCO METAL has developed AMPCOLOY® High Copper Alloys.

Resistance welding is a process that has been used in the automotive industry for decades to join metal parts together. Various automotive components such as car bodies, frames, electrical wiring, fuel tanks, exhaust systems, and many more are produced using the principles of resistance welding. But why is this method of welding so popular?

Read more in the free «AMPCO METAL guide for resistance welding and anti spatter»

First of all, let’s take a closer look at how resistance welding works: It uses heat generated by electrical resistance to fuse two pieces of metal, creating a strong and permanent bond. Invented back in 1885, resistance welding today is still one of the most frequently used welding techniques and, over the years, has become increasingly popular due to its many advantages over other welding techniques – especially in the automotive industry.


Benefits of resistance welding in the automotive industry

One of the biggest advantages of resistance welding is its speed. Unlike other welding methods, which can take several minutes to complete a single weld, resistance welding can complete the same task in a matter of seconds. This makes it ideal for use in the fast-paced automotive industry, where quick and efficient production is essential.

In addition to the speed, consistency is the other great advantage resistance welding has to offer. Because the heat generated during the welding process is controlled by electrical resistance, the process is highly repeatable and produces consistent, high-quality welds every time. This makes it an ideal choice for mass-production applications, which there are plenty of in the automotive industry.

Other advantages include the following:

  • High accuracy
  • Repeatability
  • Safe use due to very little smoke or fumes
  • Environmental friendliness compared to other welding methods

Save costs with resistance welding

Finally, resistance welding is a cost-effective option for the automotive industry. The process requires no filler materials, making it more cost-efficient than other welding methods. Furthermore, the equipment required for resistance welding is relatively inexpensive and requires minimal maintenance, reducing the production cost.

Speed, consistency, versatility, and cost-effectiveness: All these positive properties make resistance welding an ideal choice for the automotive industry – but not exclusively there. Other industries such as aerospace, electrical equipment, and consumer goods production are other examples that harness resistance welding.


Choosing the right material for your resistance welding operations

Choosing the right material for your resistance welding operations can be crucial for the end quality of your products, further enhance the cost-effectiveness of your production, or significantly increase your productivity by decreasing the amount of time wasted for downtimes. For example, choosing high copper alloys for your clamping element can help reduce the amount of weld spatter. They are highly suitable for welding electrodes, too, offering smooth functionality under elevated operating temperatures.

AMPCO METAL is a company that specializes in the production of aluminum bronzes, copper alloys, and specialty bronzes. These materials are known for their strength, hardness, and corrosion resistance, making them ideal for use in a variety of processes – including resistance welding. AMPCOLOY® High Copper Alloys are engineered with exceptional conductivity, high strength, and unique wear characteristics, delivering higher lifetime, quality, and performance. They are well suited for all of the resistance welding applications mentioned above.


For further information about resistance welding, please download our free «AMPCO METAL guide for resistance welding and anti-spatter»









Expert team AMPCO METAL