How Does Seam Welding Work?

How Does Seam Welding Work

Welding is a widely used industrial process that joins two or more parts permanently. Seam welding is a process used for welding the continuous joints of similar or dissimilar metals of varying thicknesses. Knowing the mechanics behind seam welding is important as it helps achieve quality welds, control the welding process, and improve overall productivity. This blog will closely examine how seam welding works and the factors that affect the process.

Seam welding uses a roller-shaped electrode that rotates continuously to create heat and pressure on the workpieces. The process starts with the welding electrode that moves along the joint to be welded. The electrode generates heat through resistance in the metal, which softens it and fuses it to create a continuous seam. The electrode is moved along the joint at a specific speed and pressure so that the metal is welded together uniformly.

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The process requires a proper balance between the current flow and the pressure applied by the electrode. If the current is too high than necessary, it may lead to the material overheating and causing burnouts. In contrast, if the current is too low, it may not fuse the metal, resulting in weak welds. Therefore, it is important to maintain a balance between current and pressure to achieve top-quality welds.

Seam welding is a versatile process used to weld different materials, such as steel, aluminium, nickel alloys, etc. The important thing to note is that the thickness of the material affects the welding cycle, time, and current requirements. For instance, if the material is too thin, it may require less current flow and time for successful welding. On the other hand, for thicker materials, the current flow needs to be higher, and the time required is longer.

The welding quality is highly dependent on the mechanical and electrical properties of the material. That is why it is crucial to prepare the material before welding and ensure sufficient flexibility and strength. Similarly, different materials have different electrical resistance, which affects the current flow during welding. Inconsistency in the material’s electrical resistance can lead to an undesired welding pattern, which is important to identify and correct.


In conclusion, seam welding is a reliable and efficient way to permanently join two or more parts. The process requires a balance between the current and pressure the electrode applies, which can be achieved by understanding the material’s properties and following appropriate welding procedures. The welding cycle differs between thin or thick materials, and the current flow and welding time greatly affect the quality. Knowing the mechanics of seam welding can help to control the welding process, improve productivity and achieve top-quality results.



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