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Resistance Spot Welding and Ultrasonic Inspection

Resistance spot welding is a commonly used welding process in which two or more metal pieces are joined together by applying pressure and passing an electrical current through the joint. The resistance generated by the electrical current causes the metal to heat up and ultimately form a weld. Here are some key points regarding resistance spot welding:

Speed and Efficiency
Resistance spot welding is a fast and efficient welding method. It allows for rapid joining of metal pieces, making it suitable for mass production or high-volume manufacturing processes.

Strong and Reliable Joints
The welds created by resistance spot welding are typically strong and reliable. The localized heating and pressure applied during the process result in a solid, durable bond between the metal pieces.

Suitable for Various Materials
Resistance spot welding can be used for a wide range of metals, including steel, stainless steel, aluminum, and copper alloys. However, the suitability of a particular material for spot welding depends on its electrical conductivity and thermal properties.

Applicable in Various Industries
Resistance spot welding is used in various industries, such as automotive, aerospace, electronics, and construction. It is commonly employed for joining sheet metal components, wire harnesses, and other metal assemblies.

Ultrasonic inspection, on the other hand, is a non-destructive testing method commonly used to assess the integrity and quality of welds. Ultrasonic waves are generated and sent through the weld area, and the reflections or echoes of the waves are analyzed to detect any defects or anomalies. Here are some key points regarding ultrasonic inspection for welding:

Defect Detection
Ultrasonic inspection is highly effective in detecting and characterizing internal defects in welds, such as cracks, porosity, lack of fusion, or incomplete penetration. It provides a detailed evaluation of the weld quality and helps identify areas that may require repair or further investigation.

Non-destructive Testing
Ultrasonic inspection is a non-destructive testing method, meaning it does not cause any harm or alteration to the tested material. It can be performed during or after the welding process without affecting the structural integrity of the weld.

High Resolution and Accuracy
Ultrasonic inspection offers high resolution and accuracy, allowing for precise defect characterization and sizing. It can provide detailed information about the size, depth, and orientation of a defect within the weld.

Ultrasonic inspection can be applied to various types of welds, including butt welds, fillet welds, and some special weld configurations. It can be used on different materials, thicknesses, and geometries, offering versatility in its application.

Resistance spot welding is a fast and efficient process for joining metal pieces, whereas ultrasonic inspection is used to assess weld quality and detect any potential defects or flaws. Combining these techniques can ensure the production of strong and reliable welds while ensuring their quality and integrity.

RAM Solutions is a proud supplier of VOGT Ultrasonics.  They have over 30 years of experience in spot weld inspection, and have developed PHAsis, a series of inspection systems for manual and robot-controlled spot weld inspection. PHAsis inspection systems use the imaging phased array ultrasonic technology, which achieves a very high inspection accuracy. That is why these proven inspection systems are used primarily in the automotive industry.

With PHAsis, manual spot weld inspection is combined with automated, robot-controlled spot weld inspection. Two inspection systems with a common basis, but specially optimized for their individual area of application: PHAsisNEO for manual spot weld inspection, PHAsisBLU for automated spot weld inspection. With PHAsis, customers decide quite flexibly which spots are to be inspected automatically and which manually. All inspection results and data are combined in a database, which can communicate with the customer’s QA system.

PHAsisNEO – For the manual inspection of spot welds

PHAsisNEO was specially developed for manual inspection of spot welds and longitudinal weld seams in production. The focus is on very high inspection accuracy and a high level of usability for fast and reliable inspection. The color depth display of the spot weld as a D-scan by the phased array technology makes the spot weld quality “visible”.  Due to the automatic evaluation suggestion and the imaging result display, the training effort is minimal.

PHAsisBLU – For robot-controlled inspection of spot welds

PHAsisBLU was specially developed for the automated, robot-controlled inspection of spot welds and longitudinal weld seams: Fast & precise. With the help of automated testing, significant savings potentials can be realized while at the same time achieving the best reproducibility of the measurement results. Here, man and robot work hand in hand. Inspection systems from the combination of PHAsisBLU and robot technology contribute to future-oriented quality assurance as well as to detailed documentation of the inspection results.

If you would like more info or a demo on VOGT’s PHAsisNEO or PHAsisBLU, contact RAM Solutions at 248-299-0525.