WELD 322 FINAL EXAM REVIEW
QUESTIONS AND ANSWERS | 2026
UPDATE | 100% CORRECT.
What are the three most important factors to making a good resistance weld? -
ANS Pressure, Current, Time.
Spot welding is used when the joint does not have to be: - ANS Liquid or gas tight
Why choose resistance welding? - ANS Speed, material variety, automation, fit-up tolerance
Projection welding uses what type of feature? - ANS Projections or dimples
What are some common applications of projection welding? - ANS Stampings, weld bolts,
weld nuts, weld pins
Advantages of Projection Welds? - ANS Thick to Thin, multiple welds can be made, visually
appealing.
Disadvantages of projection welds? - ANS Added manufacturing cost, higher current
requirements, increased equipment cost, and increased material cost for fasteners.
What makes seam welding different? - ANS Seam welding uses rollers for the electrodes,
which can create a continuous, gas-tight sealed weld.
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, What are some applications of seam welding? - ANS Automotive fuel tanks, exhaust systems,
stock for bodies, water/liquid storage tanks, etc.
Advantages of Seam Welding? - ANS All same advantages as spot welds, with liquid-tight
seals.
Limitations to seam welding? - ANS High current requirements, increased equipment cost,
requires water cooling, and has geometry restrictions.
What is flash welding? - ANS The faying surfaces are flashed and pressurized on either end
created by upset force after heating is completed.
What are some common uses for flash welding? - ANS Aerospace landing gear, drill pipe to
fittings for petrol, rail tracks.
What are advantages of flash welding? - ANS Variety of shapes, minimal preparation, forms
sound welds, and creates a smaller HAZ compared to upset welding.
Limitations of flash welding? - ANS High current requirements, workpieces must have the
same CSA, molten metal is expelled during the flashing, and extra cost to machine flashing off.
What is Upset Welding? - ANS A form of resistance welding where a high amperage is
produced between ends of material, and an upset pressure is added.
Is upset welding a single or multiple step process? - ANS Single
Is flash welding a single or multiple step process? - ANS Multiple
Common uses for upset welding? - ANS Continuous butt joints in the manufacturing of wire,
pipe, and tubing products.
@COPYRIGHT ALL RIGHTS RESERVED PAGE 2 OF 8
QUESTIONS AND ANSWERS | 2026
UPDATE | 100% CORRECT.
What are the three most important factors to making a good resistance weld? -
ANS Pressure, Current, Time.
Spot welding is used when the joint does not have to be: - ANS Liquid or gas tight
Why choose resistance welding? - ANS Speed, material variety, automation, fit-up tolerance
Projection welding uses what type of feature? - ANS Projections or dimples
What are some common applications of projection welding? - ANS Stampings, weld bolts,
weld nuts, weld pins
Advantages of Projection Welds? - ANS Thick to Thin, multiple welds can be made, visually
appealing.
Disadvantages of projection welds? - ANS Added manufacturing cost, higher current
requirements, increased equipment cost, and increased material cost for fasteners.
What makes seam welding different? - ANS Seam welding uses rollers for the electrodes,
which can create a continuous, gas-tight sealed weld.
@COPYRIGHT ALL RIGHTS RESERVED PAGE 1 OF 8
, What are some applications of seam welding? - ANS Automotive fuel tanks, exhaust systems,
stock for bodies, water/liquid storage tanks, etc.
Advantages of Seam Welding? - ANS All same advantages as spot welds, with liquid-tight
seals.
Limitations to seam welding? - ANS High current requirements, increased equipment cost,
requires water cooling, and has geometry restrictions.
What is flash welding? - ANS The faying surfaces are flashed and pressurized on either end
created by upset force after heating is completed.
What are some common uses for flash welding? - ANS Aerospace landing gear, drill pipe to
fittings for petrol, rail tracks.
What are advantages of flash welding? - ANS Variety of shapes, minimal preparation, forms
sound welds, and creates a smaller HAZ compared to upset welding.
Limitations of flash welding? - ANS High current requirements, workpieces must have the
same CSA, molten metal is expelled during the flashing, and extra cost to machine flashing off.
What is Upset Welding? - ANS A form of resistance welding where a high amperage is
produced between ends of material, and an upset pressure is added.
Is upset welding a single or multiple step process? - ANS Single
Is flash welding a single or multiple step process? - ANS Multiple
Common uses for upset welding? - ANS Continuous butt joints in the manufacturing of wire,
pipe, and tubing products.
@COPYRIGHT ALL RIGHTS RESERVED PAGE 2 OF 8
