Projection welding is a type of resistance welding which is very similar to the spot welding. There are few differences between projection welding and spot welding. It can also be referred as the improved version of spot welding. Projection welding differs from spot welding as per the following factors.
  • First and most important is the projection provided into the specimen of projection welding process
  • The quality of welding can be different in both the process, weld quality also depends on the material to be weld
  • The parameters of the equipment used can be different from spot welding process. So the different tools and equipment may be required.
  • The amount of current required in projection welding is less because of low resistance between the workpieces.
In the Projection welding the projection is provided to the materials to be joined or workpieces. The projection is about defining a place where the weld joint should be created. In projection welding the pieces are held together or clamped together between the electrodes and the pressure will be applied.
The working principle of projection welding is same as spot welding.
 The resistance between the specimens is responsible for the heat generation when the current is passed through. As per the projection provided, the analysis of size of weld, shape of the weld bead is to be done before creating the joint.
The heat control and proper balance of the temperature is an essential feature of projection welding for variety of materials to be used.
  1. In the process of projection welding the arrangement of all the equipment is the first need.
  2. After getting and arranging the machine the power sources will be connected to the machines.
  3. When all the required parameters are adjusted and the electrodes are ready to flow the current through the workpieces, the two specimens is to be placed between the electrodes.
  4. After this the plunger will be pushed to give the command to the machine to flow the current in the workpieces.
  5. When the current will flow, there would be the resistance between the workpieces that will cause the generation of heat.
  6. That heat will cause the melting of material and a molten material pool is created.
  7. After this the creation of joint between the pieces will take place.
  8. The process will take very few time to produce a welded joint.

  1. This process can be implemented for mass production of material joining process.
  2. It is economical because the filler material is not used.
  3. The maintenance is easy in the system of projection welding and very few times maintenance is required.
  4. The energy required id less because of low current usage and also because of less pressure requirement.
  5. The projection are able to guide the workpieces to be joined at appropriate places.
  6. Heavy and weighed material can be joined and sheets of large thickness can be provided a good quality weld joint.
  7. The life of electrodes is longer because of low current requirement.
  8. Flux is not used in this process.
  9. With the help of properly designed jigs, the large no. of joint can be produced in a quick manner.
  10. Flame is no used so requirement of safety aids is less.
  11. It is an easy process with high production rate.
  12. The heat control is very good for the joining of varies types of material.

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