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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
Formation of Projection Welds
Embossed Projection Weld
(fused nugget forms)
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
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
Projection Weld Performance Improvement:
Example 2
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.
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
Projection Welding Applications
Tubular connections
Projection Welding Applications (Contd)
Projection Welding Applications (Contd)
Fusites
Potential Projection Welding Applications
for Shipbuilding