Spot Welding Services at Acorn Metal: Precision & Efficiency

Spot welding is a fast and efficient metal joining technique, widely used in industrial applications to fuse two or more metal sheets.

At Acorn Metal, our spot welding machines create reliable, durable bonds for sheet metal assemblies. Using controlled heat and pressure, we join metals efficiently without adhesives or solder, perfect for high-volume production and precise custom projects alike.

What Is Spot Welding and How Does It Work?

Spot welding is a type of welding that works by applying electrical current and pressure through two copper alloy electrodes. These electrodes compress the metal sheets, generating heat at the contact point until the metal melts into a nugget, forming a permanent bond. This process creates a strong, clean joint with minimal preparation, making it perfect for sheet metal assemblies.

The Process at a Glance:

Surface Preparation: Metal surfaces are cleaned to remove oils, rust, or contaminants.
Machine Setup: Copper alloy electrodes are configured for pressure and conductivity.
Adjust Settings: Parameters such as current level and weld cycle duration are set based on the metal type and thickness.
Alignment: Metal sheets are accurately positioned between electrodes.
Welding: Pressure and electrical current generate heat to form a molten weld nugget.
Cooling: The nugget solidifies as we maintain pressure, ensuring a solid bond.
Completion: Once cooled, we retract the electrodes, and the welded piece is ready for further processing.

Our equipment is regularly maintained to guarantee precision and performance. We ensure every weld meets our quality standards—whether it’s a small batch or a large order.

Metals Used in Spot Welding

Spot welding is commonly used with steel-based metals, ensuring durable and reliable joints for a wide range of applications. Each project is unique, so we assess materials and tolerances on a case-by-case basis.

Our spot welding works best with:

Stainless Steel: Known for corrosion resistance, used in automotive, construction, and appliances.
Mild Steel: Offers strength and malleability, ideal for structural and industrial components.
Pre-coated Steels (Galvanised/Zinc): Often used in outdoor applications, providing weather resistance.

These metals offer excellent conductivity and heat tolerance, essential for forming strong welds with minimal distortion.

Industry Applications

Spot welding offers versatility across several industries, especially where sheet metal assemblies are required. Typical applications include:

Automotive: Body panels and structural components.
Construction: HVAC systems, cladding, and prefabricated structures.
Appliances: Internal panels, enclosures, and mounting brackets for household and commercial equipment.

Spot welding’s efficiency makes it suitable for prototyping, custom fabrication, and high-volume production runs, offering cost-effective solutions for industrial and commercial clients alike.

Design Considerations

Good design is crucial for effective spot welding. Here are a few things we do to optimise projects:

Minimise gaps between metal sheets for better contact and stronger bonds.
Avoid overlapping too many layers, which can reduce weld strength.
Mark electrode points clearly to ensure proper alignment during production.
Use spot welds in areas not exposed to water if corrosion resistance is required.

Our team at Acorn Metal works with clients to refine their designs, ensuring optimal weld placement and strength for every project.

Quality Control and Standards Compliance

We follow strict quality control procedures at every stage of the spot welding process, from setup to final inspection. While we maintain high standards of accuracy and consistency, specific certifications are not required for every project, as each is tailored to individual client specifications. Our focus is on delivering reliable, high-quality results that meet industry expectations.

Expert Metal Fabrication and Metalwork

Spot Welding