5 spot welding safety tips

Our lab gets a lot of calls asking us how to safely use resistance welding equipment, so I thought I would write a few words about the most common issues that affect safety.

Before I begin, let me first say that all resistance welding equipment should only be used by qualified and trained personnel for its intended purpose. Please take the time to read the applicable owner's manual that came with your equipment - it gives you a lot of good safety information and can save you a lot of trouble.

 

 

What if the weld creates sparks? Will it hurt my eyes?

Discharging molten material can indeed hurt your eyes or other body parts, so always wear safety glasses and a protective apron.

 

Can I get electrocuted by touching welding cables or electrodes?

Fortunately, no. For all involved, the voltages of all resistance welding techniques are below the levels that can cause electrical shock problems. This includes CD, AC, DC and HF models. While it is true that currents as low as 250 milliamps can stop the heart when applied to the chest, the body - and especially the skin - has considerable resistance. Resistance welding output voltages are usually around 3 volts and rarely exceed 10 volts, so they are not capable of sending high currents through the body.

 

Can I get caught in an electrode?

It's true. If proper safety precautions are not taken, your hand can be caught or crushed by a moving electrode. Never put your hand in the path of a moving electrode. Other options include using a tool instead of your hand to hold the part in place, or replacing the foot switch with an anti-binding palm button to keep your hand away from the moving electrode.

 

Can I get burned by touching a coil or electrode?

Yes, you can! Therefore, make sure you cool the electrodes and electrode holders properly. This can be done using forced air or water. If not properly cooled, the heat buildup may be enough to cause skin burns.

 

I have a pacemaker - do I need to consider magnetic fields?

All types of resistance welders have been in use for many years and there is no evidence that magnetic fields can cause any harm to the user. However, it is true that no formal studies have been conducted to determine whether magnetic fields around welders can have an impact on the health of operators with implanted medical devices, including pacemakers. Due to the lack of formal studies, we recommend that wearers of pacemakers or other implanted electronic devices not operate welders. In addition, I am reluctant to suggest/recommend a minimum safe distance between a resistance spot welder and a person with a pacemaker. I believe that the distance depends on many different factors and can only be determined by a qualified physician and the manufacturer of the pacemaker.