Roll Spot – Lap Weld 4mil Steel

System 1:
CD400DP-RS, 400ws CD resistance welder with roll spot programming
PASP-HP, pressure actuated single probe hand piece
Copper wheel electrode
Copper grounding rod (1/4” thick)
1awg weld cables

The steel sheets are easily lap welded using the CD400DP-RS and PASP-HP hand piece. We used a long flat copper rod about a ¼” thick and 1” wide to act as the grounding plane for the tube to slide over. 1awg weld cables were used but 6awg cables could also suffice.

Roll spot programming of the CD400DP allows the user to discharge consecutive welds with a pre-set time interval between welds. We usually set the interval to 0.1s (the minimum amount). At higher energies the time between welds actually lengthens slightly due to the time needed to recharge the capacitors. Operator hand speed is important when using the roll spot method since it will determine the actual distance between spots (the faster the motion, the further apart the spots will be). Dwelling for too long in one place can cause burnt marks or sticking.

We performed the welds pictured at an energy setting of 50ws. This setting delivers strong results but operators should feel free to experiment further with the energy to dial in even better results.

The CD400DP-RS is an ideal power supply for roll spot welding thin sheets. At slower hand speeds the roll spot method can create close to continuous seams and at higher speeds operators can place several spot welds quickly and easily. The more consistent the hand speed, the more consistent the distance between spots will be.

Let us know if you have any questions.
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