What is the projection welding process

What is a projection weld?

Projection welding is a form of resistance welding in which the design or shape of the part is used to concentrate the current during the welding process, What is the projection welding process creating discrete individual point contacts. In most applications, many small projections are formed on one surface of the parts to be welded. These projections may be rounded grooves, elongated ridges, spheres, or extended corners of the weld nut. Two round wires placed together at 90 degrees make a point contact. It can also be a projection weld.

When the mating parts are connected together, these projections concentrate the current flow and generate heat in these places. What is the projection welding process What is the projection welding process As the projections heat up the weld nugget forms and collapses. Several weld nuggets hold the part together after cooling. In the case of cross wire welding there is of course one weld per crossing point, but usually in fencing several welds are made simultaneously.

What is the projection welding process

The circular ring design at the bottom of the hydraulic fitting creates a tight hydraulic seal. What is the projection welding process Cross wire welding can be a fence or the other side of a road. The weld nut holds the various parts of your automobile in place.

The process is similar to spot welding but in this case the electrode is not used to accumulate heat. A partial plan or arrangement does this. Multiple welds can be created simultaneously when there are multiple projections. It is a very efficient process and does not depend on electrodes like spot welding. What is the projection welding process Other factors such as alignment, project stability, welder follow-up and nut welding, thread safety etc. must be controlled. Projection welds and processes have been designed and developed to suit a variety of applications.

Working Principle

By definition, different projections are formed in this welding technique. Here, the metal pieces to be joined are placed between two electrodes. A large compressive force is applied to the electrode. When current flows through the system, heat is generated due to the internal resistance of the metal workpiece. One thing you should note here is that heat is generated due to the internal resistance of the metalwork rather than electrical arcing.

What is the projection welding process They concentrate projected heat. As the electrode pressure increases, this projection collapses, forming a fused weld nugget. Thus, a quality weld is formed. In the above figure, projection means that raised joints are formed on one of the base metals, then, these base metals are placed between two electrodes and a force is applied perpendicular to the electrodes.

But as the applied force increases, those sharp projections collapse and weld deposits form on the weld surface. What is the projection welding process The image above shows the formation of weld nuggets and collapse of sharp projections.

No, you can use any size projection. The only caution you need to take when selecting fluxes is that they must be capable of concentrating the heat to produce the required weld. Commonly used forms of projection are button-type projection, cone-type projection, and spherical projection. What is the projection welding process Button-type projections are used for metal sheets of greater thickness. This thickness varies in the 24- to 13-gauge range, while conical projections are used for 12- to 5-gauge metalwork. If you have sheets of metal thicker than previously mentioned, circular projection is used.

Working Principle of Projection Welding Process

Many manufacturers prefer projection welding over other welding techniques. What is the projection welding process So do you know what is the real reason for this? Well, the answer is very simple. In figure (b), you can see that this welding technique creates several joints simultaneously. So, if you have very little time and want to produce many welds at once, What is the projection welding process projection welding is a must for you. Therefore, many manufacturers use this welding process instead of others.

  • Another important feature of projection welding is that you get longer electrode life here compared to the spot-welding process. Hence, it saves you the cost of electrodes and there is no need to replace electrodes at short intervals. What is the projection welding process Some of you may wonder why electrode life is longer in projection welding compared to spot welding? In projection welding, a weld is formed as a result of heat and applied force. But in the case of spot welding, the weld is mostly formed as a result of heat generation. So, in projection welding, the electrodes are not affected by the current you supply. And most of the applied force leads to the required weld formation. It requires very little current. Therefore, the life of the electrode in projection welding is higher than that of spot welding.
  • Sometimes, the plating material remains on the surface of the metal and this plating may develop cracks during welding. What is the projection welding process Projection welding efficiently removes the plating material and produces a high quality weld. People who want to eliminate troublesome plating adopt this welding technique.

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Now it’s time to know about its benefits. So, let us discuss some important advantages of this welding technology:

  • As mentioned above, this welding requires very low current and thus, it saves the use of electricity. What is the projection welding process Therefore, low power requirement and long electrode life are the two main advantages of this welding process.
  • There is a limitation on the thickness of the metal to be welded during spot welding. But metals of almost all thicknesses are welded in this welding.
  • It can be effectively used for welding joints located in difficult places.
  • Heat balance is an important part of any welding process and it gives good heat balance while welding.


  • This welding process is not suitable for some types of copper and brass.
  • Making a projection is a very complex process and it takes time to make a projection. What is the projection welding process Making spherical shapes is very difficult and requires a skilled person to make such projections. Height of projection should be properly maintained while making those projections.
  • This procedure is not applicable to all types of workplaces. The structure of the metal work piece must be considered during this process and there are some limitations.

Since projection welding is mostly used for mass production. What is the projection welding process There are many applications such as:

  • The automobile industry makes extensive use of projection welding.
  • This welding process is also used for fan covers and bare metal doors.
  • It is also used in the manufacture of compressor components and semiconductors.
  • Heard of Diamond Segment Welding? In diamond segment welding, projection welding is used.

So, this is the precise working principle and advantages, disadvantages and applications of projection welding. What is the projection welding process We are confident that you will find an accurate description of projection welding.

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