Projection Welding

Projection welding is a metal-joining process where heat obtained from an electrical current passed between projections or embossments causes the two mating workpieces to fuse together.  Workpieces are held together under pressure exerted by the nonconsumable electrodes.

Process Characteristics

Requires no filer metal or fluxes
Requires a performed projection, embossment, or intersection on one of the workpieces
Can produce multiple spot welds in one cycle
Uses nonconsumable, low resistance copper alloy electrodes
Is used primarily on sheet metals or on relatively low-mass workpieces
Is easily automated

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Information provided is from Manufacturing Processes Reference Guide by Robert H. Todd, Dell K. Allen, and Leo Alting.--1st ed. Published by Industrial Press Inc., 1994.