A cost-effective process that yields solid welds for long-term performance, resistance spot welding (RSW) remains a top joining method for a variety of structural parts. RSW was one of the first applications leveraged by robotics, and advances in robot hardware and software have enhanced it.

With its robust arm designs and intuitive digital interfaces, RSW is widely supported and continues to be a go-to method for a range of thin-sheet metal fabrications. The robotic welding process features a variety of innovations, such as midfrequency (1,000–2,000 Hz) inverters for direct-current welding that reduce transformer size and weight for improved spot-gun design, and servomotors that actuate spot guns for improved energy efficiency and precision over pneumatic guns.

 …