Projection Welding: An Overview

Chonghua (Cindy) Jiang

AET Integration, Inc.
50388 Dennis Ct.
Wixom, MI 48393
Cindy.jiang@aet-int.com

Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington

Definition

Projection welding is an electric resistance welding process that

produces welds by the heat obtained from the resistance to the flow
of the welding current. The resulting welds are localized at
predetermined points by projections, embossments, or intersections

(Welding Handbook, Vol. 3, Part 2, p50)

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Typical Projection Designs

a. Embossed

b. Stud-to-Plate

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c. Annular

Examples of Projection Design

Examples of Various Projection Designs Before and After Welding

(Welding Handbook, Vol. 3, Part 2, p56)

Welding in Shipbuilding
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Seattle, Washington

Examples of Annular Projections

(Welding Handbook, Vol. 3, Part 2, p58)

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Typical Commercially Available Fasteners Used

in Projection Welding

(Welding Handbook, Vol. 3, Part 2, p59)

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Projection Welding Equipment

Medium Frequency (MFDC) Machine

AC Machine

Capacitor Discharge (CD) Machine

Welding in Shipbuilding
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Projection Welding Equipment (Contd)

Welding in Shipbuilding
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Factors Affecting Heat Balance

Design and location of the projection

Thickness of the sections

Thermal and electrical conductivity of the materials

Heating rate

Electrode geometry and alloy

Tooling alignment

Weld force

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
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Formation of Projection Welds

Embossed Projection Weld
(fused nugget forms)

Annular Projection Weld

(solid state bonding develops)

Welding in Shipbuilding
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Materials Suitable for Projection Welding

Low carbon steel

Hardenable steels
Stainless steels-ferritic, martensitic, and austenitic types
Nickel-base alloys
Copper alloys
Aluminum and magnesium alloys
Titanium alloys
Coated and plated steels

(Welding Handbook, Vol. 3, Part 2, p63)

Welding in Shipbuilding
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Materials Suitable for Projection Welding-Example

Welding Trials on 1.6 mm Magnesium AZ31, AET

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Example of Project Weld PropertyMicrohardness

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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
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Projection Weld Performance Improvement:

Example 1

Issue: Weld did not pass dye penetrant test and pull test

Fracture surface

Root Causes:

No Bonding

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

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Projection Weld Performance Improvement:

Example 2

Intergranular Fracture Mode of a Projection Weld Failed during Service

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Projection Weld Performance Improvement:

Example 2 (Contd)

Base Metal

Base Metal

HAZ

Broken part with Intergranular Fracture

HAZ

Non-broken Part

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
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Projection Welding Applications

Tubular connections

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Projection Welding Applications (Contd)

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Projection Welding Applications (Contd)

Attaching nuts and stud

Sheet metal assemblies

Tank fittings and ferrules

Fusites

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Potential Projection Welding Applications

for Shipbuilding

Fabricate the metal sandwich plate of large area

Projection welding
Adhesive assisted projection welding
(STS Shipbuilding, South Korea)
(Welding in the World, v 53, n 7-8, p 5-11, 2009)

Attach nuts and stud

Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington