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Projection Welding
Projection Welding
Projection Welding
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Definition
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Typical Projection Designs
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Examples of Projection Design
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Examples of Annular Projections
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Typical Commercially Available Fasteners Used
in Projection Welding
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Projection Welding Equipment
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Projection Welding Equipment (Cont’d)
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Factors Affecting Heat Balance
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Key Process Variables
• Welding Current
– Welding current must be at least high enough to create fusion before the
projection has completely collapsed
• Weld Time
– Weld time is dependent on the welding current and projection rigidity
– Depending on the type of base metal and its surface conditions, multiple
pulses can be applied to yield the desired weld performance
• Electrode/Dies
– Proper electrode design and alloy is a major factor in making projection
welds
• Electrode Force
– Electrode force is critical for proper projection collapse without expulsion
and formation of a sound weld
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Formation of Projection Welds
Embossed Projection Weld
(fused nugget forms)
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Materials Suitable for Projection Welding
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Materials Suitable for Projection Welding-Example
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Example of Project Weld Property-
Microhardness
600
500
Microhardness (HV500g)
400
300
200
100
0
0 0.05 0.1 0.15 0.2 0.25 0.3
Distance (in.)
Weld A Weld B
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Weld Quality
• Parts preparation
– Weld area clean of grease, rust, scale, dirt or shearing burrs
– Less variance in part tolerance before welding
• Projection size and shape
• Materials
• Welding technique
• Heat balance
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Projection Weld Performance Improvement:
Example 1
• Issue: Weld did not pass dye penetrant test and pull test
• Root Causes:
– Tooling misalignment
– Insufficient forging force at the faying surface
• Actions Taken:
– Check tooling misalignment by using carbon imprints between faying surfaces
– Increase applied forging force
– Adjust welding parameters to get sufficient weld bonding area
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Projection Weld Performance Improvement:
Example 2
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Projection Weld Performance Improvement:
Example 2 (Cont’d)
Base Metal
Base Metal
HAZ HAZ
• The broken part with IG fracture shows primary ferrite along grain boundary. This generally results in
low ductility and fracture toughness.
• The base metal microstructure of the broken part with IG fracture is a result of improper heat treatment
of the base metal before it was welded.
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Process Advantages and Limitations
• Advantages
– Versatility
– Speed
– Ease of automation
– Ability to make multiple welds simultaneously
– Longer electrode/tooling life
• Limitations
– The forming of projection may require an additional step of operation
– Limitations on materials projection weldability
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Projection Welding Applications
• Tubular connections
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Projection Welding Applications (Cont’d)
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Projection Welding Applications (Cont’d)
• Fusites
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
Potential Projection Welding Applications
for Shipbuilding
Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington