Essentials of Manufacturing

Information, coverage of important developments and expert commentary in manufacturing.

CNC Machining Design Guide

Optimize your designs, reduce machining time, and lower your costs.

Injection Molding Design Guide

Guide for high quality and cost-effective plastic injection molding.

Mechanical Engineers Outlook

Guide for those interested in becoming a mechanical engineer. Includes qualifications, pay, and job duties.

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Introduction

Projection welding is a variation of spot welding. Projections are designed in one part. These act as current concentrators for the welding process. When the two parts are mated together, these projections are the high points that first make contact. As the power is cycled, the projections simultaneously carry the current and are welded. This process is known as Resistance Projection Welding, RPW.

Due to the efficiency of power transfer, thicker materials can be successfully welded. Materials as thick as 3 mm (0.125 in) can be successfully welded. For thin stock, the traditional spot welding is a preferred method.

Low carbon steels, low alloy steels, stainless steels, as well as aluminum can be welded using this process.

Projections are usually semi-spherical or blunt conical type.

Projection welding requires that the height of projections be controlled to within a range of 0.075 mm (0.003 in).

Essentials of Manufacturing

Information, coverage of important developments and expert commentary in manufacturing.

CNC Machining Design Guide

Optimize your designs, reduce machining time, and lower your costs.

Injection Molding Design Guide

Guide for high quality and cost-effective plastic injection molding.

Mechanical Engineers Outlook

Guide for those interested in becoming a mechanical engineer. Includes qualifications, pay, and job duties.