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Fusion Welding vs Resistance Welding – What’s the Difference

Fusion Welding vs Resistance Welding

In the world of welding, there are a variety of techniques that can be used to join metals together. Two of these techniques are fusion welding and resistance welding. They have similarities but also many differences. Both methods use heat to melt the material, but how they generate the heat, what conditions are needed for each process, and what metals are best suited for each type of weld will all affect which process you should choose. Let’s take a look at some of the basics behind fusion welding and resistance welding so that you can make an informed decision about which one is best for your project.

Fusion Welding Basics

Fusion welding is a process in which two pieces of metal are melted together using heat from an electric arc or gas flame generated by a torch. The molten metal combines to form a strong joint after cooling. This type of weld is typically used on thicker materials such as steel and aluminum and requires access to both sides of the material being welded. To achieve a successful fusion weld, several factors need to be taken into consideration, including electrode selection, amperage settings, arc gap distances, travel speed, and shielding gas composition.

Resistance Welding Basics

Resistance welding is similar to fusion welding in that it also uses heat generated by electricity; however, instead of using an electric arc or gas flame torch as with fusion welding, this process uses electrical resistance between two electrodes to create heat energy that melts the materials being joined together. The electrical current passes through the workpiece itself rather than an external source such as a torch or rod tip like with fusion welding. This method works best when joining thinner pieces together since less power is required than with fusion welding; however it cannot be used on thicker materials because too much power would cause damage to the part being welded. Resistance welding can be used on most metals but works best on parts made from copper-based alloys due to their high electrical conductivity.

Difference Between Fusion Welding and Resistance Welding

Advantages of Fusion Welding

Fusion welding has several advantages over other types of welding. First, fusion welds are generally stronger than other types of welds. Second, fusion welds are less likely to leak than other types of welds. Third, fusion welds are less likely to crack or break than other types of welds. Finally, fusion welds can be performed in a variety of environments, including underwater and in space.

Advantages of Resistance Welding

Resistance welding also has several advantages over other types of welding. First, resistance welds are typically faster and cheaper to perform than fusion welds. Second, resistance welds do not require an external heat source, making them ideal for use in difficult-to-reach places. Third, resistance welds are less likely to cause warping or distortion in the material being welded. Finally, resistance welds can be performed in a variety of environments, including underwater and in space.

Disadvantages of Fusion Welding

Fusion welding also has several disadvantages when compared to other types of welding. First, fusion welds require an external heat source, which can be expensive and difficult to set up. Second, fusion welds can cause warping or distortion in the material being welded. Third, fusion welds take longer to perform than other types of welds. Finally, fusion welds can be dangerous if not performed properly due to the risk of fire and explosion.

Disadvantages of Resistance Welding

While resistance welding has several advantages over other types of welding, it also has some disadvantages. First, resistance welding can only be used on certain materials, such as sheet metal or wire. Second, resistance welding produces harmful fumes that must be properly ventilated

Conclusion:

Both fusion and resistance welding offer advantages depending on your project requirements. Fusion welding requires more equipment but offers greater flexibility in terms of material thicknesses that can be joined successfully; however it also requires access to both sides of the material being welded which may not always be possible if you have limited space or access points available. Resistance welding requires less equipment but is better suited for joining thinner materials due its lower power requirements; however parts must be made from copper-based alloys for this method to work effectively since these metals are highly electrically conductive. Ultimately it’s up to you to decide which method will work best for your specific application based on cost considerations, accessibility constraints, and material compatibility requirements so do your research before deciding which technique is right for you!

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