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Seam Welding It's Working principle, Advantages, Disadvantages and Applications

The concept of seam welding is similar to spot welding. In spot welding electrodes are disc shaped and after each weld electrodes are not separated but maintain continuous pressure on the part.

The movement of electrodes and current instinct are arranged in that the weld nuggets overlap set up a gas or a fluid pressure tight weld. The overlap depends upon ratio of current. The overlap is generally 30 to 50 percent.

Seam Welding It's Working principle, Advantages, Disadvantages and Applications

Seam welding is a type of resistance welding process used to join metal parts along a continuous seam. It is commonly used for the fabrication of cylindrical or rectangular structures, such as pipes, tubes, and tanks, where a leak-proof joint is required.

The seam welding process involves clamping two overlapping metal sheets or plates together and passing an electric current through them. The current generates heat due to the resistance of the metal, causing the surfaces in contact to melt and fuse together. Electrodes, typically in the form of rotating wheels or rotating wheel and stationary bar, are used to apply pressure to the workpieces and maintain electrical contact.

Types of seam welding:

Resistance Seam Welding: In this method, two wheel-shaped electrodes are used—one rotating and the other stationary. The workpieces are placed between the electrodes, and pressure is applied as the rotating wheel moves along the joint, creating a continuous weld.

Electric Upset Seam Welding: This technique uses two rotating wheel-shaped electrodes. As the wheels rotate, they pinch and squeeze the workpieces together, creating the necessary pressure for the weld. The current is then passed through the rotating electrodes, creating localized heating and fusion along the seam.

Seam welding offers several advantages, including high productivity, consistent weld quality, and airtight joints. It is commonly used in industries such as automotive, aerospace, and manufacturing for applications like fuel tanks, exhaust systems, pressure vessels, and various structural components.

It's worth noting that while seam welding is a widely used process, there are other welding methods available, such as spot welding, TIG (tungsten inert gas) welding, and MIG (metal inert gas) welding, each with its own specific applications and advantages.

In seam welding copper alloy is used for to keeping the heat on electrode contact surfaces to minimum. The part and electrode are flooded with water to dissipate heat.

Classification of Seam Welding 

a) Continuous motion welding 

In continuous motion method electrodes are rotated at fix constant speed. And the current impulses to obtain overlapping weld. For too thicker sheets are use for welding that time continuous motion welding is used.

b) Intermittent motion welding 

In intermittent motion welding the work pieces pass till the next weld position, stop for the welding to take place and it automatically pass to another weld position, stop again for welding.  Method is suitable for thicker sheets.

Types of Seam Welding

a) Lap seam welding

b) Butt seam welding

Advantages of seam welding

Seam welding offers several advantages that make it a popular choice for joining metal parts. Here are some of its main advantages:

High Productivity: Seam welding is a continuous welding process, which means it can produce long, uninterrupted welds. This leads to higher productivity compared to other welding methods that require frequent starts and stops.

Consistent Weld Quality: Seam welding provides consistent and uniform welds along the entire seam. The process controls, such as electrode pressure and current, can be precisely regulated, resulting in reliable and repeatable weld quality.

Airtight Joints: Seam welding is particularly useful when airtight or leak-proof joints are required. The continuous weld created by seam welding ensures a tight seal, making it suitable for applications such as fuel tanks, pressure vessels, and pipelines.

Reduced Distortion: The localized heating in seam welding minimizes heat-affected zones and reduces distortion in the workpieces. This is beneficial for maintaining the dimensional stability of the welded parts, especially in applications with strict tolerances.

Versatility: Seam welding can be performed on various types of metals, including carbon steel, stainless steel, and aluminum. It is adaptable to different sheet thicknesses and can handle both straight and curved seams, making it versatile for a wide range of applications.

Automation Potential: Seam welding can be easily automated, allowing for high-volume production with minimal operator intervention. Automated systems can be programmed to perform the welding process consistently, ensuring efficiency and reducing labor costs.

Cost-effective: With its high productivity and consistent weld quality, seam welding offers cost savings in terms of reduced labor, increased throughput, and minimized rework or repair requirements.

These advantages make seam welding a preferred choice in industries where efficiency, quality, and reliability are crucial, such as automotive manufacturing, aerospace, construction, and industrial fabrication.

Disadvantages of Seam Welding

While seam welding offers several advantages, it also has some disadvantages and limitations. Some of the main disadvantages of seam welding:

Limited Joint Configurations: Seam welding is most suitable for joining flat or cylindrical parts with overlapping edges. It is less effective for complex joint configurations, such as T-joints or corner joints. In such cases, other welding methods like spot welding or TIG welding may be more appropriate.

Restricted Access: The electrodes used in seam welding need access to both sides of the joint to create a continuous weld. This requirement can restrict its use in situations where the backside of the joint is inaccessible or obstructed, making it challenging to achieve complete weld coverage.

Equipment Setup and Maintenance: Seam welding requires specialized equipment, including rotating wheel electrodes or electrode wheels and associated machinery. The setup and maintenance of such equipment can be more complex and time-consuming compared to simpler welding processes.

Limited Thickness Range: Seam welding is best suited for thin to medium-thickness materials. If the metal sheets or plates are too thin, there is a risk of burn-through or excessive distortion. On the other hand, if the material is too thick, achieving proper fusion and penetration along the entire seam may be challenging.

Weld Appearance: The continuous nature of seam welding can result in a visible weld bead along the joint. In certain applications where aesthetics are important, this visible weld bead may require additional finishing or cosmetic treatments.

Lack of Joint Strength: Depending on the specific joint configuration and welding parameters, seam welding may not provide the same level of joint strength as other welding methods like fusion welding. The fusion zone in seam welding is relatively narrow, and the joint strength can be influenced by factors such as electrode pressure and welding speed.

Limited Repairability: In cases where a defect or failure occurs in a seam weld, repairing or reworking the weld can be challenging. Accessing the interior of the welded joint without damaging the surrounding areas can be difficult, often leading to the need for complete replacement rather than repair.

It's important to consider these disadvantages and evaluate whether seam welding is the most suitable method for a specific application. Other welding processes may be more appropriate depending on the joint type, material thickness, access limitations, and desired weld characteristics.

Applications of Seam Welding

Seam welding finds applications in various industries where the joining of metal parts along a continuous seam is required. Some common applications of seam welding include:

Automotive Industry: Seam welding is extensively used in the automotive industry for manufacturing vehicle components. It is employed in the production of fuel tanks, exhaust systems, engine cradles, suspension components, body panels, and frames. The airtight and leak-proof welds achieved through seam welding are crucial for fuel containment and ensuring the structural integrity of automotive assemblies.

Aerospace Industry: Seam welding is utilized in the aerospace sector for the fabrication of components requiring high strength, durability, and tight tolerances. It is employed in the production of aircraft fuselages, wings, fuel tanks, and structural members. The consistent and reliable weld quality provided by seam welding is essential in maintaining the structural integrity and safety of aerospace structures.

Pressure Vessels and Tanks: Seam welding is commonly used in the manufacturing of pressure vessels, tanks, and containers used in industries such as oil and gas, chemical processing, and power generation. These applications require welds that are leak-proof and capable of withstanding high internal pressures. Seam welding provides a continuous weld along the entire seam, ensuring the required strength and integrity.

Pipelines: The construction of pipelines for transportation of oil, gas, water, or other fluids often involves seam welding. Longitudinal seams of pipes are welded using automated seam welding processes to create strong and reliable joints. The continuous welds produced by seam welding ensure the pipeline's integrity and prevent leakage.

HVAC and Refrigeration: Seam welding is utilized in the production of heat exchangers, air conditioning units, and refrigeration systems. The tight and continuous welds achieved through seam welding ensure efficient heat transfer and prevent refrigerant leakage, ensuring the optimal performance and longevity of these systems.

Electrical Enclosures: Seam welding is used in the manufacturing of electrical enclosures, such as control cabinets, switchgear cabinets, and transformer housings. The continuous welds provide structural strength, electromagnetic shielding, and protection against environmental factors such as dust, moisture, and corrosive agents.

Industrial Fabrication: Seam welding is employed in various industrial fabrication applications where continuous and leak-proof welds are required. It finds use in the production of metal ductwork, conveyor systems, storage containers, and structural components.

These are just a few examples of the many applications of seam welding. The process's versatility, high productivity, and ability to create strong, continuous welds make it a widely used joining method in various industries where efficiency, reliability, and structural integrity are crucial.

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