There are multiple welding procedures in the market, and different welders opt for distinctive procedures depending on the nature of their projects. Well, projection welding is another outclass method used in multiple fields. But remember, you need to be an expert if you want to deal with this procedure.
Projection welding is the form of resistance welding that uses current and pressure in combination to give out robust welds. But what is the exact procedure behind this welding method? Here in this detailed article, we will talk about projection welding and tell you how it stands contrary to spot welding. Let’s begin promptly.
What is Projection Welding?
Projection welding is a popular type of resistance welding. It uses pressure and temperature to weld different projections uniformly. Whether the projections are round, rib types, extended, circular or elongated ridges, this welding method will give outstanding results.
As copper is a good conductor of electricity and heat, so copper electrodes are used in this technique.
Types of Projection Welding
There are two types of projection welding.
- Embossed projection welding
- Solid projection welding
Advantages of projection Welding.
Projection welding stands superior to many other welding techniques because of the following reasons.
- The top advantage of projection welding is that you can weld more than one spot in a single stroke.
- Clean welds are obtained with this welding method.
- This method is quicker and more effective as compared to other welding methods.
- If you own a manufacturing company then this welding method is a life savior for you. It consumes relatively less power so it can reduce your annual expenditure.
- Minimum heat is required so electrodes face less wear and tear; this means your electrodes will last longer than usual.
- Minimal to no limitations are associated with this welding method.
- You can use this welding procedure for automation with zero worries.
The procedure of Projection Welding- A step-by-step approach
Copper electrodes are used and are set in position after the cleaning of the metals. You will have to place one electrode below and one above both metal pieces.
The electrodes are meant to provide pressure and keep metals in place.
Electrical current is supplied to these electrodes, which eventually get transferred to the metals.
Heat is produced due to internal resistance.
Projection welding is the technique where all the heat is projected towards the junctions where you want the welds to be finalized.
As both sheets are in contact, the final welds are formed immediately.
What are the most appropriate materials for projection welding?
Copper is the welders’ best and most preferred material to perform projection welding. All because of its good thermal and electrical conductivity.
Applications of Projection Welding.
Projection welding is used to weld nuts, studs, plates and bolts.
It is greatly preferred by automobile industries, sheet metal works, ship industries, and many other fields.
It is also used to weld different parts of refrigerators, grills, and compressors.
Key Similarities Between Projection Welding and Spot Welding
These methods are extensively used by many industries as both have quite a similar procedure. Both of them totally work by deriving electrical current and heat. The heat produced will melt the filler, and the metal electrodes are there to hold both metal parts in place and provide electrical current as well.
The only visible difference is the heat and current intensity used in both methods.
Projection Welding vs Spot Welding
|Projection Welding||Spot Welding|
|Projection welding utilizes less heat and pressure||Relatively higher amounts of heat and pressure are used.|
|Copper is the most commonly used metal for this type of welding||Silver is excellent and the most commonly used metal.|
|It is useful for thick metals||It can work on both thin and moderately thick metal sheets|
|This method gives out relatively stronger welds as compared to other ones||Weaker and smaller welds are obtained|
|Straight electrodes are preferred||Pointed tip electrodes are used
|Expensive equipment is used, so it is a costly method||Relatively cheaper method
|Superior heat and current balance, so electrodes are least affected||High heat levels are used, so there is more wear and tear on electrodes.|
Frequently Asked Questions
1. What types of machines are used for projection welding?
Projection welding is a great method that can be used in different industrial procedures. But it can be costly because of the expensive machinery used. There are three types of machines used for projection welding, i.e., Rocker arm types machines, portable welders, and press type machines.
2. What are the safety precautions for projection welding?
If you want to obtain accurate results with projection welding, then make sure to follow all of the essential safety precautions.
● Make sure that the welder is cool before you make any adjustments
● Never forget to wear gloves and glasses
● Using a face shield is a plus point.
● Don’t touch over-heated electrodes
● Take good care of electrical current and the earth wire
3. Can we measure projection welding strength?
The strength of the projection welding can be measured by approximation. By measuring the area of the dimple and then assuming base metal properties for tensile strength. This is the only way you can measure projection welding strength.
Here comes the end point of this journey. We hope that we are done with the disclosure of all of the facts regarding projection welding. Also, all of the differences between spot welding and projection welding are discussed in this article.
Reading this in detail means you are there with all of the clear welding concepts.