Welding Engineering Program - Projection Welding

A set of flashcards designed to help review key concepts, advantages, disadvantages, applications, and technical requirements of Projection Welding in welding engineering.

What are the basic steps of Projection Welding?

Force is applied with no current, current flow softens the projection, projection collapses and weld fusion occurs, resulting in a completed weld.

What are the advantages of Projection Welding?

It allows for easier heat balance, can weld greater thicknesses, provides uniform results, increases machine output, extends electrode life, and shortens weld time.

What is a typical application for Projection Welding?

Used for parts that are too thick for spot welding and for large size differences between parts.

What are the requirements for a projection in sheet material?

It must be rigid enough to support initial weld force, large enough to avoid collapse, and must allow for intimate contact post-welding.

What is the primary function of electrode force in Projection Welding?

To hold the projection against the mating part during weld time and ensure complete collapse to minimize sheet separation.

What are the two common designs of projections?

Button or Bubble design, which is the most common, and Annular design, which features a single ring projection.

What is one disadvantage of Projection Welding?

It requires additional operations to form projections and precise control for alignment of welding dies.

What is the effect of welding time on projection weld formation?

Welding time affects stages of strength formation and sheet separation, from initial cold set-down to full nugget development.

How does welding current affect Projection Welding?

Welding current influences the diameter of the fused zone and the strength characteristics of the weld.

What are some typical dimensions for projection welding?

Typical dimensions include various thicknesses, heights, and diameters depending on the gauge material being welded.