Resistance welding — suitable thickness range for seam welding Continuous resistance seam welding is most suitable for producing leak-tight joints within which thickness range of sheet metals?

Introduction / Context:
Resistance seam welding uses rotating wheel electrodes to create overlapping nuggets forming a continuous weld. It is widely used for thin sheet fabrications such as fuel tanks, drums, and sealed containers where leak-tightness is essential.

Given Data / Assumptions:

• Joint type: lap joints in sheet metals.
• Process: resistance seam welding with controlled current pulses and wheel pressure.
• Objective: typical thickness capability rather than absolute limits for special machines.

Concept / Approach:
Seam welding is optimized for thin gauges because current density, heat generation, and nugget overlap must be controlled precisely without excessive expulsion. Standard installations handle from foil-like thicknesses (tens of microns) up to about 3 mm total stack for reliable, consistent seams. Thicker sections demand very high current and force, making process control and electrode life problematic.

Step-by-Step Solution:

Verification / Alternative check:
Application catalogs from seam welder manufacturers list optimal single-sheet thicknesses in the sub-millimeter to low-millimeter range, with total lap thickness typically not exceeding about 3 mm for routine production.

Why Other Options Are Wrong:

• 3–5 mm, 5–8 mm, 8–10 mm, 10–15 mm: beyond common economic and technical limits for seam welding and more suited to arc or laser seams.

Common Pitfalls:
Confusing seam welding with spot welding capability; attempting thick stacks that cause expulsion, burn-through, or poor nugget overlap.

Final Answer: