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Projection Welding

Projection Welding
Learning Activities
Lesson Objectives 1. View Slides;
When you finish this lesson you will 2. Read Notes,
understand: 3. Listen to lecture
• The advantages and limitation of 4. Do on-line
projection welding workbook
• Projection design for various
thickness materials
• Typical Applications of the process

Keywords
Projection Welding, Projection Design, Thin Material
Projections, Thick Material Projections
Introduction to Projection
Welding

(a) (b) (c) (d)

[Reference: Welding Handbook, Volume 2, p.566, AWS]


Examples of Various Projection Designs

(a)
(b)

(c) (d) (e)


[Reference: Welding Handbook, Volume 2, p.562, AWS]
Examples of Various Projection
Designs (CONT.)

(f) (g) (h)

(i) (j)
[Reference: Welding Handbook, Volume 2, p.562, AWS]
Considerations for Various Materials
• Mild and HSLA Steels:
– Both are considered readily projection weldable.
– Both can adequately retain projection welding shape until
adequate heating has occurred and are weldable using either
embossed or solid projections.
– The HSLA steels may, depending on the particular composition,
suffer an array of metallurgical problems.

• Galvanized Steels:
– Projection welding can offer some major advantages in resistance
welding galvanized steel.
– The relatively low contact resistance is a major concern.
– The use of a projection can put contact resistance back into the
welding circuit directly at the faying surface. This, in turn, results
in lower welding currents and possibly better electrode-life
characteristics as compared to resistance spot welding.
Considerations for Various Materials
(CONT.)
• Aluminum and Aluminum Alloys:
– They are considered not projection weldable.
– Most aluminum alloys are of too low a strength to allow the
projection to survive under the necessary welding forces.
– The oxide formed appears to prevent the solid-state bond necessary
to form the type of joint.

• High Alloy Steels:


– Projection welding is also quite readily applicable to the higher
alloy steels.
– The major concern here is material hardenability. Adequate
precautions must be taken to prevent the development of brittle
microstructures.
Considerations for Various Materials
(CONT.)
• Copper Alloys:
– Projection welding has definite implied advantages for
resistance welding copper and its alloys. Just as for the
galvanized steels, the weld circuit resistance can be localized at
the faying surface.
– Effective projection welding is largely a function of the specific
copper alloy used.
– With respect to embossed projection welding, the suitability for
welding appears to vary with the material strength level.
– Higher-strength copper alloys are relatively projection
weldable. However, lower-strength alloys appear to have
difficulty retaining projection shape under the applied welding
force.
– Most copper alloys appear to be weldable with one or more
forms of solid projection welding
Advantages of Projection
Welding
• Ease of obtaining satisfactory heat balance
for welding difficult combinations

• More uniform results in many applications

• Increased output per machine because


several welds are being made
simultaneously
Advantages of Projection
Welding (CONT.)
• Welds may be placed more closely together

• Parts are more easily welded in an assembly


fixture

• Finish, or surface appearance, is often


improved

• Parts may be projection welded that could not


be otherwise resistance welded
Limitations of Projection
Welding
 Requires an additional operation to form projections

 Requires accurate control of projection height and


precise alignment of the welding dies with multiple
welds

 Requires thickness limitation for sheet metals

 Requires higher capacity equipment than spot


welding
Requirements for A Projection in
Sheet Material
• Rigid enough to support the initial weld force before current
is applied.
• Sufficient mass to raise a spot or weld nugget in the plane
surface to welding temperature. If it is too small it will
collapse before the other surface is heated.
• Collapse without extruding between the parts.
• Surfaces should be in intimate contact after welding.
• Not be partially sheared. Such projections are weak, tear out
easily and are of low shear strength.
• Easy to form, so that the punch and die require little
maintenance.
• Cause minimal distortion of the part during forming.
Basic Projection Design in Steel
Sheet
Punch Die
Spherical
A
Radius D 45°
T

H
15°
Projection
Wall D B
Thickness Should Point Radius
Be at Least 70% Projection Should Blend “R”
of Sheet Thickness into Stock Surface without
Shouldering

[Reference: Welding Handbook, Volume 2, p.563, AWS]


Bubble - Button Type Projections
(a) (c)

(b) (d)
<T

[Reference: Resistance Welding Manual, p.3-3, RWMA]


Projections for 0.500-in & 0.250-
in Stock
120°
60° 90°
0.52” 45°
0.15”
0.094” 0.45”

0.50”
0.25”

When the thickness is greater than 0.125-in, the projection will not be
completely forged back

[Reference: Resistance Welding Manual, p.3-4, RWMA]


Embossed Annular Projection

[Reference: Resistance Welding Manual, p.3-5, RWMA]


Punch & Die Dimensions for
Spherical Dome Projections

[Reference: Welding Handbook, Volume 2, p.563, AWS]


Projection Types for Sheet and
Solid Applications

Spherical Projections

Elongated Projections

[Reference: Metals Handbook, Volume 6 (Welding, Brazing and


Soldering), p.503-524, ASM]
Projection Types for Sheet and
Solid Applications (CONT.)

Annular Projections Annular Projection on


Pin-and-Tenon Joint

Pyramidal Projections Cross-Wire Weld

[Reference: Metals Handbook, Volume 6 (Welding, Brazing and


Soldering), p.503-524, ASM]
Projection Welded Front Axle and
Radiator Support for Tractors

[Reference: Resistance Welding Manual, p.3-4, RWMA]

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