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Projection Welding

Metal components are welded together using projection welding, a resistance welding technique that concentrates heat at specific locations called projections. The purpose of these projections is to produce localized heat on the workpieces, which causes the materials to melt and bond. Because of the technique’s accuracy and efficiency, which guarantee robust and long-lasting welds in a variety of applications, it is widely employed in the industrial industry.

Types of Projection Welding

Welding in Spot Projection
Welding in Spot Projection

Spot projection welding is the process of welding at a particular location where a projection exists on the workpiece.

Welding of Seam Projection
Welding of Seam Projection

A continuous line of projections is seen on the workpieces during seam projection welding.

Welding Grid Projection
Welding Grid Projection

When using grid projection welding, one or both workpieces have a pattern of projections placed in a grid or matrix.

Welding of Flange Projection
Welding of Flange Projection

Securing a flange or lip from one workpiece to a flat surface on another is the process of projection welding.

Welding with Embossed Projection
Welding with Embossed Projection

To attach components having raised or embossed features, embossed projection welding is utilized.

Welding with Upset Projection
Welding with Upset Projection

When utilizing upset projection welding, a welding current is passed through two or more projections on the workpieces that come into contact.

Welding with Percussion
Welding with Percussion

A form of projection welding called percussion welding occurs when the projections collide simultaneously with the application of the welding current.

Flattening Projection Welding
Flattening Projection Welding

Flattening projection welding is the process of bringing two flat workpieces with projections into contact.

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The Projection Welding Process

Organizing Workpieces
Organizing Workpieces
Materials Selection
Materials Selection
Projection Designs
Projection Designs
Workpieces Fixing
Workpieces Fixing
Choosing Electrode
Choosing Electrode
Use of Force
Use of Force
Utilizing Current
Utilizing Current
Weld Procedure Cycle
Weld Procedure Cycle
Defrosting&Consolidation
Defrosting&Consolidation
Superior Examination
Superior Examination
Following Weld Procedures
Following Weld Procedures
Record-Keeping
Record-Keeping

The Benefits of Projection Welding

Increased Output: The technique makes it possible to finish multiple welds at once, which raises industrial output.

Extended Life: Due to their reduced heat and pressure usage throughout the welding process, projection welds are more durable than spot welds.

Adjustability: The projection welding technique is easily adapted to function with a range of parts and components by modifying its settings.

Utilization Ease: Multiple welds can be completed simultaneously when using projection welding, however, this requires highly automated equipment.

Neat Appearance: By focusing the point of contact on one side and using less force, projective welding reduces surface imperfections at the welded seam and improves surface smoothness.

More Intimate Welding: Because each junction is under less pressure when projection welding equipment is employed, welds are spaced closer together.

Projection Welding Applications

Automobile – Bolts, nuts, and screws are examples of fasteners that can be joined to flat surfaces via projection welding.

End-user Products – The fasteners in consumer items including fans and fan covers, furniture, and household appliances are secured by manufacturers via projection welding.

Establishment – Thick plates, hollow metal doors, and metal panels are just a few of the construction-related items that are produced using projection welding.

Mechanical – In mechanical equipment, projection welding connects coverings, crossing wires, and fasteners to bars.

Semi-Conductor – Projections welds’ tight fit is ideal for hermetically sealed semiconductor equipment since it seals out gases and air that could hinder the equipment’s functionality.

Particularities Between Projection Welding and Spot Welding

Projection Welding
  • Since projection welding produces a weld with less heat and pressure, it is more beneficial for thick metal components and items that need an extraordinarily strong junction.
  • Because projection welds are less noticeable than spot welds, the finished product could seem nicer.
Spot welding
  • The most used type of welding is spot welding, which differs from projection welding in a few key areas.
  • This method is usually used to link huge metal sheets or parts together. It involves flowing metal currents along the junction.
What kind of materials are typically employed in projection welding?

Projection welding helps work with a variety of metals due to its adaptability, including:

  • Aluminum
  • Stainless steel
  • Carbon steel
  • And other alloys.
Is projection welding suitable for high-volume production?

Projection welding works effectively in large-scale manufacturing. 

This method is quick and effective, which makes it perfect for companies that need a lot of welded parts.

What types of projections are used in projection welding?

There are several shapes that projections can take, including circular, rectangular, and other types. 

Can projection welding be automated?

To improve consistency and efficiency in the welding process, projection welding is indeed easily automatable.

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