Spot welding machines: types, how to choose, best models

Rating of spot welding machines

The adhesion of the materials is ensured by a seam consisting of many small welded points. To create them, the part is placed between two electrodes; they compress it from below and from above, while simultaneously passing current. There are two types of welding machines - portable and stationary. We conducted research on several dozen devices, evaluating each on a number of indicators:

• Category – household, industrial, professional;
• Type – pliers, portable apparatus, stationary machine;
• Welding method – single-sided, double-sided, combined version;
• Current – ​​maximum indicator, equipment capabilities from 3000 to 10,000 A;
• Speed ​​of work - how many hitch points are left per minute;
• Permissible thickness of materials - which sheets can be overlapped;
• Voltage – single-phase 220 V, three-phase 380 V;
• Control - ease of use, manual, synergistic (microprocessor) setting;
• Noise level – sound pressure in dB during active mode;
• Power – the parameter is measured in kW, the higher it is, the thicker the surface;
• Additional options – cooling system, equipment.

The demand for such devices has been growing over the years. Manufacturers are improving their products, adding new products to the market. We have selected products that have received the highest ratings from experts and the most favorable reviews from customers and ordinary owners. As a result, 7 nominees were identified - 4 ticks, 3 spotters.

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Types of equipment

When resistance spot welding, the machine can produce current of different types and frequencies. Based on these distinctive features, welding equipment is divided into four classes:

• resistance spot welding on alternating current;
• low-frequency resistance welding;
• capacitor type devices;
• DC welding.

There are multi-point resistance welding machines for welding meshes in production. In such devices, welding occurs simultaneously at several points. Any equipment has its advantages, but single-point AC devices have become the most popular.

Spot welding pliers

The tong is a spot welding machine that is distinguished by its mobility. The weight of this design usually does not exceed 10 kg, and for ease of use a special suspension is used. It can easily cope with work in hard-to-reach places, not inferior to the performance characteristics of stationary models. We have selected 4 clear leaders in terms of the number of positive reviews, reliability, and value for money.

Caliber SVA-1.5 AK

A Russian-made welding machine, the main task of which is household resistance welding. It is powered by a single-phase 220 V network, while the maximum power consumption does not exceed 8 kW. The IP20 standard indicates protection against dust. The control method is completely manual, the master himself sets the required current strength, clamping force, and for convenience, a handle and spare tips are included. To fix the compression force of the pliers, the design is equipped with a limiter bolt, it is located under the movable handle. The recommended thickness of the metal sheet is 1.5+1.5 mm. Sold in a package with dimensions 520x140x245 mm, weight 13.8 kg. The maximum welding current is 220 V, leaving 3 points in one minute.

Advantages:

• Reliable return spring for spreading the pliers;
• Neat points;
• Ergonomic handle for rearranging;
• Ease of Management;
• Small sizes;
• Inexpensive.

Flaws:

• Not for working with products of different thicknesses;
• The wiring must be 4 mm² cross-section.

Reviews confirm that pliers do an excellent job with several sheets of metal (even up to 5 pieces), if they are of the same thickness. It can be steel, copper, aluminum, sheet metal. To operate, you need to connect to an outlet; they do not require any electrodes, argon, or wire.

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Telwin Digital Modular 230

Portable single-phase device with microprocessor control of the new “Fuzzy Logic” system. Its main purpose is to improve the quality of welding while simplifying operation. You can automatically configure the operating time and current strength in advance, taking into account the thickness of the metal sheets; it can be 2+2 mm. There are two modes for performing tasks - constant, pulse. The pliers exert pressure on products weighing from 40 to 120 kg; this criterion can also be adjusted. There is a system of protection against overheating due to the design made of heat-insulating material, as well as IP20 - from dust, moisture, and third-party objects. The maximum power level is 13 kW, the current is 6000 A. With dimensions of 440x100x185, the structure weighs 10.5 kg.

Advantages:

• Synchronous electronic timer;
• Flexible settings system;
• Two operating modes;
• Suitable for high strength steel sheets;
• Reliability of the design;
• Performance.

Flaws:

• Requirements for the power supply network;
• The case heats up in continuous mode.

Such equipment can be used in continuous mode on pre-cleaned metal, this guarantees sufficient productivity. The pulse allows for adhesion of untreated surfaces. Modern alloys allow accurate results to be achieved if medium frequency DC is used.

Tecna 7900

Lightweight compact pliers made in Italy for double-sided welding. Unlike its predecessors, this model is equipped with a special timer (2-65 cycles). An air cooling system is built in to protect against overheating. For complex work with thin metal, stainless steel, and small-diameter rods, current adjustment and a manual compression drive are provided. The maximum power rating is 2 kW and power consumption is up to 9.5 kW at a current of 13,000 A and a point leaving speed of 60 pieces per hour. The dimensions of the structure are 90x370x230 mm with a weight of 10.5 kg, it is covered with class F insulating material. The size of the metal sheet is 2+2 mm if it is low-carbon steel, 6+6 mm for rods.

Advantages:

• Built-in timer;
• Air cooling;
• Thermal insulation;
• Manual compression drive;
• Professional class;
• Compactness.

Flaws:

• Price;
• Low speed of issuing points (1 per minute).

Can be used both at home and on construction sites, in auto repair shops. Interaction with oxidized steel, surfaces with paint residues, and black tin is allowed. In production, they are most often used to create structures from reinforcement and manufacture ventilation equipment.

Blueweld Plus 230

A portable machine for resistance spot welding, equipped with microprocessor control according to the modern Fuzzy Logic system. It is allowed to work with only type St3 sheet metal with a thickness of 2+2 mm. The power reaches 13 kW at a current of 6300 A. The owner can adjust the time and current level, taking into account the characteristics of the materials used. This can be either a continuous mode or a pulse mode for products with a high elasticity coefficient. Lever pressure - from 40 to 120 kg. To avoid overheating, the handle is protected with a special insulating coating. The reliable design has dimensions of 440x100x185 mm, its weight is 10.3 kg. To protect the system from power surges, special overload protection with light indication is provided.

Advantages:

• Ergonomic handle;
• Modern microcontroller;
• Overheat protection;
• High power factor;
• Operation by right-handers, left-handers;
• Flexible settings.

Flaws:

• Price;
• For ease of use, you need to buy consoles.

The thoughtful design allows you to easily perform tasks for both right-handed and left-handed people. The length of the electrodes is only 120 mm, which allows you to cook in hard-to-reach places. Electronic synchronizer ensures precision. The dots are smooth, without melted or torn edges.

The main difference and technical parameters

Most models are presented in the same form:

• A device by which the contact welding process occurs;
• Grounding cable;
• The wire to which the current is supplied is attached to the end of the welding gun - the main element.

For greater efficiency, the gun can be equipped with various attachments, so the user can make any repairs without any problems.

There are controls on the front panel that make it possible to adjust the tool by power and current, which is very useful for working with some parts. Modern models have an informative screen that allows you to see the current technical parameters, which allows you to keep the process under control.

Spot welding spotters

A spotter is a type of hand-held spot welding device, useful in the repair of transport equipment and at construction sites. It demonstrates greater efficiency when interacting with large products when access to the inside is impossible. Sold as a standard set - the device itself, grounding cable, power supply wire, welding gun. We analyzed the opinions of craftsmen, customer reviews, tested the most popular models, identifying 3 clear leaders.

Fubag TS 2600

Spotter for one-sided tack welding on metal products up to 1.5 mm thick. With compact dimensions of 200x320x180 mm, the device consumes a voltage of 5.4 kW, delivering a current of 2800 A. The kit is supplemented with a gun, a carbon electrode and three “stars”, a rod with a reverse hammer. There are several operating modes (5 in total) - heating with a carbon electrode, welding of corrugated wire and rings, tack with stars. Thanks to the reverse hammer and 1.1 kg weight, you can quickly pull out dents. The weight of the structure is 14 kg. The manufacturer provides all the necessary tools. Additional functions - thermal protection, ignition control.

Advantages:

• Reliable connection;
• Light indication;
• Complete set of tools;
• 5 modes;
• Easy to set up;
• Compactness.

Flaws:

• Difficult to move due to heavy weight;
• There is no option to adjust the current in amperes.

Consuming high voltage, the device is recommended to be used in the country, in the garage. The model was originally designed for auto body repair, straightening, and removing dents from steel surfaces by pulling, pulling, and straightening.

FoxWeld SW-2500

A semi-automatic transformer provides capacitor welding with a discharge time of 1 to 3 ms. The entire workflow is fully automated, so even a beginner can use the FoxWeld SW-2500. The penetration depth is the minimum possible - approximately 0.1 mm, this allows operations on thin-walled metals of 0.6 mm. At the same time, parts and products are not subject to perforation, deformation, or change color. The kit consists of a gun, a power source, a clamp-mass, collets and keys for changing them. The case measures 355x355x155 mm and weighs 14.5 kg. Power 2.5 kW, pin diameter should not be more than 10 mm. For ease of control, a digital display is installed on the front wall. The speed of formation of coupling points is 10-20 pieces per minute.

Advantages:

• High performance;
• Digital display;
• Wide scope of application;
• Nice kit;
• Accurate result;
• Easy to use.

Flaws:

• Cables cannot withstand low temperatures;
• Price.

According to the characteristics and declared capabilities, the device is classified as a professional category. Can work with steel, stainless steel, aluminum, brass. Used in building construction, instrument making, electronics industry, etc.

TCC SW-1600

Ultrasonic spot welding machine for connecting studs using the capacitor method. This is an instantaneous discharge of energy at a speed of 1-3 ms or 10-20 pieces per minute. The minimum thickness of the metal sheet should be 0.6 mm, without leaving any marks. Power consumption 1.6 kW. A digital display is provided for control. The set consists of a network cable, a power supply, a gun on the wires, a ground clamp, collets and keys for replacing them. The manufacturer also provides a warranty. The degree of protection against moisture and dust here is higher than that of previous nominees - IP21. With dimensions of 355x355x155 mm, the structure weighs 18 kg.

Advantages:

• High precision ultrasound;
• Digital display;
• Performance;
• Speed;
• Nice kit;
• Professional series.

Flaws:

• Price;
• Not always available in stores.

You can use this device if you have to work with brass, steel, or aluminum. Its main difference is saving energy consumption and the owner’s time. This is a new product from a Russian manufacturer, created with modern technologies. Withstands both domestic and industrial loads.

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Device and characteristics

The spotter consists of a welder module for resistance welding, and this can be an option for both direct and alternating current.

Adjacent to this block is a ground wire and a cable ending with a special welding gun.

At the end of the latter, depending on the specifics of the work, various attachments are attached.

On the front panel of the welder there are controls for setting various welding modes, power, current, and advanced units also have a display that displays real operating parameters, allowing you to fine-tune the equipment and monitor the progress of the process.

The work of the spotter looks like this:

• The battery is removed from the car.
• The ground wire is fixed to the body.
• The gun with the nozzle is brought to the repair area.
• The electrical circuit is completed by pressing the trigger, which results in the flow of current.
• At the point of contact of the nozzle with the body, the temperature rises until the electrode is welded to the metal, but this prevents overheating of the part and its through burning.
• The next step is to pull out the dent.

Material

The contents of modern spotters are hidden in a body made of sheet metal or aluminum; sometimes individual elements made entirely of impact-resistant plastic are used, such as the back cover and carrying handle.

The front panel is metal; adjustment knobs can also be made of metal or plastic.

Legs with rubber pads are attached to the bottom of the welder, which increases its stability.

Visually, the device strongly resembles a welding inverter.

NOTE:

For ease of movement around the workshop, some models are assembled on the basis of a vertical metal cart with wheels.

Dimensions and weight

Depending on the design, the weight of the spotter can vary widely.

Portable options weigh on average 14 - 25 kg, and models assembled on a trolley can weigh up to 90 - 100 kg.

As a rule, the dimensions of the spotter are within the following limits:

• for portable options (mm) – 210 – 390x 260 – 360 x 155 – 240
• for models with a trolley (mm) – 1000 – 1800 x 500 – 600 x 700 – 950

Operating modes and power

Modern spotters are equipped with electronic control, which allows you to simply select from the available operating modes and set the required contact time, after which the device will automatically stop supplying voltage to the gun.

The operating modes of the device are numbered and additionally indicated by corresponding icons.

The following main operating modes are distinguished:

1. Welding is performed with a reverse hammer or puller, and the mode itself is designed to remove dents of small diameter and shallow depth.

   
   Considering that such damage occurs extremely often, it is in this mode that a greater amount of work is performed, especially since modern materials from which car bodies are made easily return to their original shape due to elasticity.

2. Using special electrodes, any pulling element is welded to the metal. Due to this, it is possible to correct significant defects, for example, restore jammed ribs and thresholds.
3. A short-length copper-plated electrode is used, which is used to deposit convexities formed, for example, by a ground terminal.
4. Used to heat a decent surface area using a carbon electrode. If you pull out a large damaged surface, a so-called “pop” is formed, which in this mode is eliminated due to the deposition of metal.
5. During the repair process, it is often necessary to remove fastenings, for example, moldings. Upon completion of the work, they must be welded, for which copper-plated electrodes are used.
6. The mode is suitable for pulling out metal with hooks and rings using a reverse type hammer weighing 2.5 kg, but its main purpose is welding the washer for securing the ground terminal.
7. A copper-plated electrode with a magnet is used, through which the welded bolt is held. It is used for welding bolts, installing ground terminals, and brake pipes.

One of the main characteristics of a spotter is its power.

We are talking about the output current, the maximum value of which should ideally not be lower than 3 thousand amperes.

Different tasks require their own current strength:

• Welding rings and triangles – 800 – 1000 A.
• Welding corrugated wire – 1 – 1.2 thousand A.
• Work with a copper electrode - 1.4 thousand A.
• Working with a graphite electrode to heat the surface - 2.2 thousand A.

Spotter attachments

The spotter works using the following main accessories:

• The return hammer is a removable part of the gun, for the operation of which various tips are used.
• Puller - designed for express extraction, that is, it allows you to correct minor damage by smoothly leveling the surface. Structurally, it consists of a lever mechanism.

Dents can be pulled out using a needle or star attachment, which is inserted into a reverse hammer and directly welded to the part.

A hook is also often used, but it is not welded directly, but hooked onto previously welded washers.

How to choose a spot welding machine

Not only price and financial capabilities decide which resistance welding machine to buy. Much depends on the goals, scope of application, as well as technical performance characteristics. We familiarized ourselves with the recommendations of experienced craftsmen, after which we identified the primary criteria - exposure mode, maximum possible welding current, metal thickness, control method, and power consumption.

Impact mode

Modern models operate in two modes of influence on workpieces and parts:

• One-way mode. It is more typical for spotters that are equipped with a gun with a rod, a reverse hammer with an electrode at the end. To weld, you need to grab this part to the surface and perform reverse blows to pull out the metal. This method is appropriate if the impact is carried out in hard-to-reach places, as well as when interacting with large products.
• Two-way mode. This method is appropriate if you need to overlap metal. Ticks that grip the area on both sides will cope with this task. The distance of the points will depend on the reach of the consoles, usually 12-50 cm. The upper console is movable; it is lowered by pressing while simultaneously heating.

Maximum welding current

The capabilities of the equipment directly depend on the welding current limit. For example, if the device produces 3000 A, the overall cross-section will be able to connect parts 3 mm thick. If the parameter is increased to 6000 A, then 4-5 mm steel is “stitched”. Such capabilities are demonstrated by household models; for industrial purposes, reinforced equipment of 10,000-16,000 A has been created, which corresponds to a total thickness of 9 mm.

Thickness of welded metals

This criterion also cannot be ignored when choosing welding equipment. If the instructions indicate that pliers or a spotter will grip sheets 3 mm thick, then work with wider surfaces will be of poor quality. The parameter is designated in two ways - total (for example, 6 mm) or separate (3+3 mm). Industrial versions are capable of simultaneously fastening 3 sheets, then the parameter will be 3+3+3 mm.

Control method

Everyday tasks can be easily solved by a simplified model with manual control. Budget products do not provide for adjusting the current strength, always operating at maximum. With pliers, the operator will need to independently squeeze the consoles, controlling the contact of the electrodes.

Modern, industrial designs are equipped with a synergistic microprocessor control method. For this purpose, a digital panel is provided, where the wizard indicates the type of connection and the thickness of the product. The smart system independently selects the optimal mode and turns on and off the current at the right time. All that remains is to bring the electrodes to the foot area.

Power

The power indicator is selected taking into account the surfaces that will be processed. Refractory metals require a device on which the current can be adjusted over a wide range. For ordinary metal, the standard spot welding option is suitable. A parameter within 5 kW will withstand single-phase voltage, everything above that requires additional measures or a 380 V network.

What you need to know about spotters?

The quality of work as a spotter directly depends on the experience of the operator. Following several rules will protect the master from troubles:

• Work comfort can be ensured by clearing the cleaned area of ​​the body from dust, as otherwise a large number of sparks may form. As a result, tip consumption increases.
• The ground terminal should be installed at the minimum possible distance from the welding point.

Attention!

Do not fix the ground terminal to an adjacent part.

• During work, it is necessary to monitor the quality of contact of the mass and at the point of attachment of the tool. If the contact is poor, this will certainly lead to breakage of the tool attachment point, as well as breakdown.
• It is necessary to pull the material on the damaged area in a spiral, moving from the periphery to the center. This method will save time, as it will eliminate excessive stretching of the material and the appearance of dips around the center of the dent.

Important!

The device should be connected to the outlet using wiring with a cross-section of at least 2.5 sq. mm.

If you plan to use an extension cord, then the cable cross-section should be higher based on the length.

Which spot welding machine is better?

The welding machine must be reliable, productive, and as accurate as possible in performing its functions. All presented nominees meet these parameters, reviews confirm this. The recommendations of Vyborexperta.ru will tell you what to choose and buy based on a comparative analysis of the pros and cons of each position:

• Caliber SVA-1.5 AK is a budget compact model of Russian-made pliers;
• Telwin Digital Modular 230 – device with a timer for high-strength steel sheets;
• Blueweld Plus 230 – high power, left-handed/right-handed model, microcontroller;
• Fubag TS 2600 – compact spotter with 5 operating modes, light indication;
• TCC SW-1600 is the highest indicator of accuracy, speed, and efficiency.

The choice of such a welding device should be approached with complete seriousness. In order for the costs to be justified, all factors are taken into account in advance. Conventionally, the nominees can be divided into household and professional designs. Much depends on the frequency of use, level of load, personal needs, and which products will be repaired.

User voting

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How to treat the body after welding

The metal must be clean before welding begins. But in its process it will inevitably be oxidized. For protection, a primary primer is used, it is called a primer.

The primer can be acidic (phosphate, reactive, there are many names, but the essence is the same, it is an etching primer) or epoxy.

The first works better against oxide residues, but protects worse in the long term. Epoxy is good as protection, you can put putty on it and the second layer of primer - filler - holds better. Putty should not be applied to an acid primer.

There is no clear choice; the master must decide, he knows better than the conditions. But then everything goes according to technology - the seams are protected with body sealant and painted or coated with protective compounds for the underbody.

It is possible to use compositions for hidden cavities. The main task is to completely block the access of moisture and oxygen to the overheated metal of the weld, the resistance of which has been lost, even if alloying additives were present in it.

Advantages and disadvantages of the method

Like any other method of hot metal joining, the contact-point method has a number of advantages:

• high productivity, especially when using automatic machines;
• low scrap yield, high-quality homogeneous compounds are formed;
• the seam is strong, bears bending and torsion loads;
• no consumables are needed for surfacing; a diffusion layer is formed when the rod melts;
• work is carried out in any spatial position;
• equipment comes in two types: stationary and portable;
• By adjusting the parameters of the operating current, they select the mode for any type of rods:
• no residual stresses are created in the metal.

Along with the advantages, the method has disadvantages:

• the preparatory stage takes a lot of time - there are special requirements for the contact area with the electrodes;
• physical effort is required;
• high energy consumption;
• you need a powerful current source;
• When working with manual equipment, both hands are used, the compression force is limited by the physical capabilities of the welder.

How to weld a car body with a semi-automatic machine

Welding is carried out with short stitches or points (welding rivets). In the second case, a hole is drilled (usually at the site of the factory point), after which it is welded, both parts are fused and the gap is filled with metal.

If the metal is very thin, then there is no point in greatly reducing the welding current. You need to use short touches, quickly pressing the torch button, to throw the metal wire onto the sheets, not allowing them to burn out. After which it is more confident to melt the resulting thickened seam, giving it a marketable appearance and strength.

You cannot cook with glasses, especially without any protection at all, closing your eyes at the moment you press the button. It is necessary to use a “chameleon” type mask, which automatically shades when the arc is ignited and returns transparency immediately after the button is released. All processes will be perfectly visible, quality is guaranteed.

Features of car body welding

The main specificity of welding body iron is its small thickness. The car body is designed and manufactured for minimum weight, so thin rolled sheets are used, and strength is ensured by the three-dimensional design and reinforcement in the right places.

There are also massive parts, but there are not many of them, and they do not create problems during welding. Therefore, the main thing in this kind of repair is to orient the equipment, technology and experience of the contractor to work with a small thickness of steel sheet, less than a millimeter.

In the factory, spot welding is used. The body parts are compressed by the vise of the conductors, after which the welding robot, with its tongs, sets the points at which two or more sheets of metal are melted and firmly fastened.

It is difficult to implement this method during repairs, and there is no need for it. Spot welding is a typical conveyor technology.

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The second feature is the absence of continuous seams. Under such an impact, the metal will be strongly moved and change its geometric dimensions.

If, out of ignorance and for reasons of increased strength, one side of the body is welded in this way, then it may turn out to be several centimeters shorter than the opposite one, and the body will be irreparably damaged. Therefore, they weld, simulating spot welding, with short stitches, observing the symmetry of heating the metal parts.

Welding the body with an electrode

If there is an urgent need to use manual welding, then you should take a thin electrode, an inverter with deep current regulation and try to select a mode using the same principle that was described for welding a thin sheet with a semi-automatic machine. That is, with quick touches, not allowing the metal to burn out.

No stitches can be made in one pass. And electrodes are best used for alternating current; they are the best to ignite and hold the arc from the inverter. Rather, it will be a problem to quickly pay it off.

Is it possible to cook a car body with an inverter?

If you use the word “inverter” as a designation for a manual arc apparatus, then there will be a lot of inconvenience, but it can be boiled. An example method is described above. As for the true meaning of the term “inverter”, other devices now simply do not exist for a long time; they are all inverter, including any semi-automatic device.