Arc Welding vs Resistance Welding – What’s the Difference

Arc Welding vs Resistance Welding

Welding is crucial in numerous industries, including automotive, aerospace, construction, and many others. In welding, two metal parts are joined by melting or fusing to form a strong bond. However, choosing the right welding process can be overwhelming, especially for beginners. Various welding techniques are available, but the most commonly used methods are arc welding and resistance welding. This blog will examine the fundamental differences between the two techniques to help you make an informed decision.

Difference Between Arc Welding and Resistance Welding

Principle of Operation:

Arc welding is a process of welding where electricity is passed between an electrode and the metal part to be welded. The electricity creates an electric arc, which heats the metal parts to a molten state. The molten parts then fuse, creating a strong joint between them. On the other hand, resistance welding involves the passage of an electric current through the metal parts to be joined. The heat generated from the current melts the metal, and pressure is applied to create a bond.

Application Range:

The arc welding technique suits almost any metal, including stainless steel, cast iron, steel, copper, and aluminium. It is commonly used for repairing metal parts, welding pipelines, and constructing metal structures. In contrast, resistance welding is commonly used in manufacturing industries for joining sheet metals, wires, and pipes. It is used in the automotive industry to weld door panels, chassis, and other components.

Power Supply Requirements:

Depending on the welding type and application, arc welding uses a direct current (DC) or alternating current (AC) power supply. In addition, arc welding requires a high-voltage power supply for proper operation. Resistance welding, on the other hand, uses an alternating current power source with a low voltage supply. This power source makes it ideal for welding thin sheet metals.

Weld Quality:

The weld quality of arc welding is high, creating strong and durable joints. Arc welding can produce high-quality welds on thick and thin metal sheets and is commonly used where high-quality welding is required. On the other hand, resistance welding also produces high-quality welds on thin metal sheets but may need to work better for thick metal sheets.

Environmental Considerations:

Arc welding produces fumes, smoke, and noise, generating heat. In contrast, resistance welding produces few fumes and smoke and generates less heat. Due to its environmental impact, arc welding is not recommended for use in residential areas, while resistance welding is more environmentally friendly.


In conclusion, arc welding and resistance welding are essential in several industries. When selecting the appropriate welding process, you must consider the operation principle, application range, power supply requirements, weld quality, and environmental considerations. By understanding these differences, you can make a more informed decision about which process suits your welding needs.

Minal Jogale

Minal Jogale

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