Physics of Projection Welding

Physics of Projection Welding
Projection Physics
Learning Activities
Lesson Objectives 1. View Slides;
When you finish this lesson you will 2. Read Notes,
understand: 3. Listen to lecture
The collapse of the projection during 4. Do on-line
welding workbook
Factors effecting the projection
collapse
Keywords
Current Concentration, Projection Collapse
Projection Welding of Low Carbon Steel (Two Equal Thicknesses)
[Reference: Resistance Welding Manual, p.3-13, RWMA]

Functions of Electrode Force
The electrode force must hold the projection firmly against the
mating part during the initial period of weld time where the current
density is high and the collapse rate is rapid.
The electrode force must cause complete collapse after welding, so

the resulting sheet separation is minimized.
The electrode force has a major influence on the degree of porosity

in the weld nugget. It must be low enough to give proper projection
collapse without metal expulsion and yet high enough to produce
comparatively sound welds.
The suitable dynamic force characteristic must prevail without

producing excessive initial impact force.
Effect of Weld Time
Tensile-Shear Strength
4500
4000
Nugget Diameter
3500
3000
(lbs)
2500
2000
1500
1000
500
Projection 0
0 1 4 6 10 12 16 20
Collapse
Weld Time (Cycles) Weld Time (Cycles)

Factors Affecting Heat Balance
Projection Design
Part Thickness
Die Material Backing up

the Weld
Metal Conductivity
Heating Speed
Projection Weld Formation
Stage 1 Stage 3
Stage 2 Stage 4

Projection Weld Formation
(CONT.)
Stage 5 Stage 7
Stage 6 Stage 8

Link to projection weld video
Recommended Projection
Designs
T(in.) D(in.) H(in.) L(in.)
T L
H 0.010-0.014 0.055 0.015 1/8
0.016-0.020 0.067 0.017 5/32
0.025 0.081 0.020 3/16
0.031-0.034 0.094 0.022 7/32
0.044-0.050 0.119 0.028 9/32
0.062-0.070 0.156 0.035 3/8
0.078 0.187 0.041 7/16
D 0.094 0.218 0.048 1/2
0.109 0.250 0.054 5/8
0.125 0.281 0.060 11/16
0.140 0.312 0.066 3/4
0.156 0.343 0.072 13/16
T: Thickness of thinnest outside piece
0.171 0.375 0.078 7/8
D: Diameter of projection 0.187 0.406 0.085 15/16
H: Height of projection 0.203 0.437 0.091 1
L: Minimum contacting overlap 0.250 0.531 0.110 1-1/4
[Reference: Recommended practice for resistance welding, AWS

Document C1.1-66, AWS, 1966]
Effect of Welding Time
Stage 1 Stage 5
Stage 2 Stage 6
Stage 3 Stage 7
Stage 4 Stage 8

Variation in Weld Head Position
during Projection Welding 0.062-inch
Initial Collapse
Thick Steel
Final Collapse
Current
Nugget
Electrode Expansion
Position Weld Cool
60 Cycle Timing Trace
[Reference: A study of projection welding, Welding Journal Research

Supplement, 27(12), p.712s-713s, Hess & Childs]
Variation in Weld Force during
Projection Welding 0.125-inch Thick
Steel
1000 lbs.
Weld Cool
Time

Effect of Welding Current
20,000
30 cycles
Welding Current, Amps
45 cycles
15,000 60 cycles
10,000 [Reference: A study of

projection welding, Welding
Projection: D = 0.40 Journal Research Supplement,
H = 0.027 27(12), p.712s-713s, Hess &
Electrode Force: 1500 lbs Childs]
5,000
0 0.25 0.50
Diameter of Fused Zone, in.
Relations between Weld Current, Weld
Time and Weld Strength on 0.040-inch
Thick Mild Steel
1500
Weld Strength, lbs
Shear
1000
Nominal Tension
[Reference: Further studies in

500
Projection projection welding, Welding
D = 0.10 Journal Research Supplement,
10 cycles H = 0.025
15 cycles Electrode Force 28(1), p.15s-23s, Hess & Childs]
20cycles 400 lbs
4000 5000 6000 7000

Effect of Projection Shape
1500
Shear
Weld Strength, lbs
1000
Normal Tension
500

Projections Electrode Force projection welding, Welding
D H lbs
0.010 0.025 400 Journal Research Supplement,
0.140 0.025 450 28(1), p.15s-23s, Hess & Childs]
4000 5000 6000 7000
Effect of Electrode Material
RWMA Classification
Group B, Class 12
0.20
Fused Zone Diameter, inches
RWMA
Classification RWMA Classification
Group A, Class 3 Group A, Class 2
0.10
Weld Time: 15 cycles
0
5000 4000 6000 7000
[Reference: Further studies in projection welding, Welding
Journal Research Supplement, 28(1), p.15s-23s, Hess & Childs]
Effect of Weld Spacing on
Nugget Development
(a) 1-in. Spacing
(b) 3/4-in. Spacing (c) 1/2-in. Spacing

Additive Effect of Projection Weld
Strengths for Multiple Welded
Assemblies
Projection: Weld Current:
4000 D = 0.10 No. of welds x 6340 Amps
H = 0.025 Electrode Force:
AISI 1010 No. of welds x 400 lbs
Weld Strength, lbs
AISI 1015
Weld Spacing: 0.75
3000 AISI 1020 Shear
2000

1000
Normal Tension Journal Research Supplement,
28(1), p.15s-23s, Hess & Childs]
0
0 1 2 3 4
Number of Welds
Variations in Projection Weld
Hardness
400 Thickness: 0.125
1020
Hardness, VPN
300
1015
1010
200
Fused Zone
100
0 0.25 0.50 0.75 1.00
Distance across Weld, inches
Effect of Material Hardenability
on Weld Strength
Projection:
1500 D = 0.10
H = 0.025
Weld Strength, lbs
Shear Electrode Force:

400 lbs
1000
Normal Tension
500
AISI 1010
Weld Time: Journal Research Supplement,
AISI 1015
0 15 cycles AISI 1020 28(1), p.15s-23s, Hess & Childs]
4000 5000 6000 7000
Cold Projection Collapse
Annular : 0.110 Diam.
Spherical: 0.075 Diam.
Projection Height, inches
Spherical: 0.085 Diam.

0.020 Spherical: 0.065 Diam.
0.010
0
0 100 200 300
Electrode Force, lbs
[Reference: The projection welding of 0.010 and 0.020 inch steel sheet,
Welding Journal Research Supplement, 29(9), p.3-13, Nippes & Gerken]
Nugget Development Using Spherical
Projections for 0.020-in. Thick Steel
3760 Amps 4950 Amps
4260 Amps 5330 Amps
Nugget Development Using Annular Projections
for 0.020-in. Thick Steel
4740 Amps 5100 Amps
5520 Amps 5940 Amps
Current Range Characteristics
Annular Projection 0.020-1010 Steel
Height: 0.015
Diameter: 0.110
Plug Diameter, inches
0.20 Weld Time: 6 cycles

Electrode Force: 225 lbs
0.10
Spherical Projection
Height: 0.020
Diameter: 0.075
Weld Time: 6 cycles
0
2000 3000 4000 5000 6000
Weld Current, Amps
Strength Characteristics
Spherical Projection
Height: 0.020 Diameter: 0.075
0.020-1010 Steel
Weld Time: 6 cycles Pickled in 50% HCl
Shear Strength
200 Normal Tension
Load, lbs
100
Annular Projection
Height: 0.016
Diameter: 0.077
Electrode Force: 110lbs
Shear Strength
Normal Tension
0
1000 2000 3000 4000
Effect of Weld Force on Strength
Characteristics
Annular Projection
Height: 0.015 Diameter: 0.110 Shear
Weld Time: 6 cycles
200 Electrode Force: 110 lbs
Load, lbs
Normal Tension
100
0.020-1010 Steel
0
2000 3000 4000 5000 6000
Projection Welding Schedule of
Light-Gauge Steels

Additive Effect of Multiple Projection
Welds
Annular Projection
Height: 0.015
Diameter: 0.110
1000 Shear
Normal Tension
Theoretical
0.020-1010 Steel
Load, lbs
500
Weld Time: 6 cycles

Weld Current: 5200 Amps/weld
Weld Pressure: 225 lbs/weld
0
0 1 2 3 4
Number of Welds
Projection Design for Light-
Gauge Steels
0.010
0.020
Sheet Projection Projection Punch Top Punch
Thickness Diameter Height Diameter Height
30 0.040 in. in. in. in. in.
0.010 0.110 0.015

30 0.062 0.020 0.110 0.015
0.040 0.140 0.025 0.058 0.035
0.062 0.170 0.042 0.094 0.045
0.125 0.300 0.055 0.176 0.058
30
0.125
Typical Embossed Projection Design for
Heavy-Gauge Steel Sheets
120
60 90
0.52 45
0.15
0.094 0.45
0.50
0.25

Recommended Projection Geometries and
Punch & Die Design for Heavy-Gauge
Steel Sheets

Projection Dimensions Vs. Sheet
Thickness
0.60
Projection Dimension, inches
0.50
Diameter
0.40
0.30
[Reference: Projection welding of steel
0.20 in heavy gauges and in dissimilar
thicknesses, Welding Journal Research
0.10 Height Supplement, 31(3), p.113s-125s,
Nippes & Gerken]
0 0.10 0.20
Electrode Force and Current Sequence
for Heavy-Gauge Steel Sheets
Force
Current
Time
Electrode Force and Current Sequence for
Heavy-Gauge Steel Sheets (CONT.)
Force
Current
Time
Nugget Vs. Current for Different Weld
Times
0.8
Diameter, inches
0.6

0.4 Weld Time: 250 cycles
20,000 22,000 24,000 26,000 28,000 30,000

[Reference: Projection welding of steel in heavy gauges and in dissimilar
thicknesses, Welding Journal Research Supplement, 31(3), p.113s-125s,
Nippes & Gerken]
Nugget Size Vs. Welding Current for
Different Electrode Forces
0.8
Diameter, inches
0.6
0.4
20,000 22,000 24,000 26,000 28,000 30,000
Nippes & Gerken]
Weld Strength Vs. Welding Current
Two step current start, total weld time

250 cycles 20 cycles for each step
28 225 cycles weld time, forge force applied
for first 25 cycles and end of weld
24
Load, lbs x 102
Shear Strength
20
16
Normal Strength
12
15,000 20,000 25,000 30,000

Nippes & Gerken]

Physics of Projection Welding

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Physics of Projection Welding

Uploaded by

Copyright:

Available Formats

Physics of Projection Welding

[Reference: Resistance Welding Manual, p.3-13, RWMA]

The electrode force must cause complete collapse after welding, so

The electrode force has a major influence on the degree of porosity

The suitable dynamic force characteristic must prevail without

Weld Time (Cycles) Weld Time (Cycles)

Die Material Backing up

[Reference: Resistance Welding Manual, p.3-9, RWMA]

[Reference: Resistance Welding Manual, p.3-9, RWMA]

[Reference: Recommended practice for resistance welding, AWS

[Reference: Resistance Welding Manual, p.3-9, RWMA]

60 Cycle Timing Trace

[Reference: A study of projection welding, Welding Journal Research

[Reference: A study of projection welding, Welding Journal Research

10,000 [Reference: A study of

[Reference: Further studies in

4000 5000 6000 7000

[Reference: Further studies in

Weld Time: 15 cycles

(a) 1-in. Spacing

(b) 3/4-in. Spacing (c) 1/2-in. Spacing

[Reference: A study of projection welding, Welding Journal Research

[Reference: Further studies in

Shear Electrode Force:

Spherical: 0.085 Diam.

3760 Amps 4950 Amps

4260 Amps 5330 Amps

4740 Amps 5100 Amps

5520 Amps 5940 Amps

0.20 Weld Time: 6 cycles

[Reference: Resistance Welding Manual, p.3-13, RWMA]

Weld Time: 6 cycles

0.010 0.110 0.015

[Reference: Resistance Welding Manual, p.3-4, RWMA]

[Reference: Resistance Welding Manual, p.3-15, RWMA]

Weld Time: 150 cycles

20,000 22,000 24,000 26,000 28,000 30,000

Two step current start, total weld time

15,000 20,000 25,000 30,000

You might also like