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2b1 Projection
2b1 Projection
Projection Welding
Learning Activities
Lesson Objectives 1. View Slides;
When you finish this lesson you will 2. Read Notes,
understand: 3. Listen to lecture
• The advantages and limitation of 4. Do on-line
projection welding workbook
• Projection design for various
thickness materials
• Typical Applications of the process
Keywords
Projection Welding, Projection Design, Thin Material
Projections, Thick Material Projections
Introduction to Projection
Welding
(a)
(b)
(i) (j)
[Reference: Welding Handbook, Volume 2, p.562, AWS]
Considerations for Various Materials
• Mild and HSLA Steels:
– Both are considered readily projection weldable.
– Both can adequately retain projection welding shape until
adequate heating has occurred and are weldable using either
embossed or solid projections.
– The HSLA steels may, depending on the particular composition,
suffer an array of metallurgical problems.
• Galvanized Steels:
– Projection welding can offer some major advantages in resistance
welding galvanized steel.
– The relatively low contact resistance is a major concern.
– The use of a projection can put contact resistance back into the
welding circuit directly at the faying surface. This, in turn, results
in lower welding currents and possibly better electrode-life
characteristics as compared to resistance spot welding.
Considerations for Various Materials
(CONT.)
• Aluminum and Aluminum Alloys:
– They are considered not projection weldable.
– Most aluminum alloys are of too low a strength to allow the
projection to survive under the necessary welding forces.
– The oxide formed appears to prevent the solid-state bond necessary
to form the type of joint.
H
15°
Projection
Wall D B
Thickness Should Point Radius
Be at Least 70% Projection Should Blend “R”
of Sheet Thickness into Stock Surface without
Shouldering
(b) (d)
<T
0.50”
0.25”
When the thickness is greater than 0.125-in, the projection will not be
completely forged back
Spherical Projections
Elongated Projections