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Fusion vs Resistance Welding – What’s the Difference

Fusion vs Resistance welding

Welding is a key process used in many industries. It is the process of joining two pieces of metal together by melting them and allowing them to fuse, either through the application of heat or through pressure. There are two main types of welding: fusion welding and resistance welding. Here, we will discuss the differences between these two methods.

Fusion Welding

Fusion welding is a process where two pieces of metal are joined together by melting them and applying pressure or heat to form one part. The most common type of fusion welding is arc welding, which uses an electric current to generate an arc that melts the metal. This type of welding is often used for large-scale industrial projects, such as when constructing bridges or buildings. Other types of fusion welding include gas welding and resistance spot welding.

Resistance Welding

Resistance welding involves using electricity to join two pieces of metal without melting them. Instead, it uses electrical resistance to create heat, which bonds the metals together. This method is often used for smaller projects such as wiring harnesses or automotive components like mufflers and exhaust systems. The primary benefit of this type of welding is that it can be done quickly and efficiently since it does not require additional heating elements or cooling time after the weld has been completed.

Difference Between Fusion and Resistance welding

  • Fusion welding is a type of welding that uses heat to melt two pieces of metal together.
  • Resistance welding is a type of welding that uses electrical current to weld two pieces of metal together.
  • Fusion welding is more common than resistance welding, as it is easier to achieve and maintain the required temperatures for fusion welding.
  • Resistance welding is more efficient than fusion welding, requiring less energy to weld the same material.
  • Fusion welding is typically used for thicker materials, while resistance welding is typically used for thinner materials.


When choosing between fusion vs resistance welding, you must consider what your project requires and what type of materials you’re working with. Fusion welding can provide strong joints on large projects. Still, it can take longer than other methods due to its reliance on additional heating elements and cooling times after completing each weld. On the other hand, resistance welding offers quick results with minimal preparation time. Still, it may not be suitable for larger projects due to its limited strength capabilities compared to fusion methods. Understanding these differences will help you make an informed decision about which method best suits your needs!

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