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)

Welding in Shipbuilding
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Seattle, Washington
 Typical Projection Designs

a. Embossed b. Stud-to-Plate c. Annular

Welding in Shipbuilding
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Seattle, Washington
 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)

Welding in Shipbuilding
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Seattle, Washington
Typical Commercially Available Fasteners Used
in Projection Welding

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

Welding in Shipbuilding
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Seattle, Washington
Projection Welding Equipment

Medium Frequency (MFDC) Machine

AC Machine
Capacitor Discharge (CD) Machine

Welding in Shipbuilding
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Seattle, Washington
Projection Welding Equipment (Contd)

Welding in Shipbuilding
May 10-11, 2011
Seattle, Washington
 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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Seattle, Washington
 Formation of Projection Welds
Embossed Projection Weld
(fused nugget forms)

Annular Projection Weld

(solid state bonding develops)

Welding in Shipbuilding
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Seattle, Washington
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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Seattle, Washington
Materials Suitable for Projection Welding-Example

Welding Trials on 1.6 mm Magnesium AZ31, AET

Welding in Shipbuilding
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Seattle, Washington
 Example of Project Weld Property-
Microhardness

Microhardness Traverse of Two Projection Welds

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

Fracture surface No Bonding

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
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Seattle, Washington
Projection Weld Performance Improvement:
Example 2

Intergranular Fracture Mode of a Projection Weld Failed during Service

Welding in Shipbuilding
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 Projection Weld Performance Improvement:
Example 2 (Contd)

Base Metal
Base Metal

HAZ HAZ

Broken part with Intergranular Fracture 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
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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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Seattle, Washington
 Projection Welding Applications

Tubular connections

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Projection Welding Applications (Contd)

Welding in Shipbuilding
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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