Projection Design & Equipment

Projection Equipment
Learning Activities
Lesson Objectives 1. View Slides;
When you finish this lesson you will 2. Read Notes,
understand: 3. Listen to lecture
• Equipment requirements necessary 4. Do on-line
for successful projection welding workbook

Keywords
Projection Weld Electrodes, Low Inertia Electrode Holders,
Projection Punch and Die Set
 5.0 Equipment Requirements

1.5.1 Electrodes and Describe the design of electrodes and

Electrode Holders electrode holders, and its significance

Describe the design of die assemblies

1.5.2 Die Assemblies and its significance
 Types of Electrodes
• Large flat electrodes, often made from bar stock
– Not recommended on weldments which are distorted from the
projection forming operation
– Advisable when welding a few projections in a localized area

• A series of local contact surfaces made by relieving a bar between

projections or by brazing inserts of hard copper alloy to the bar
• Tend to equalize the total current and force in spite of distortion or
tolerance of the weldment
– Recommended as best for all projection welding, and especially in
those applications involving four or more projections.

• Composite type electrodes

 Type of Electrodes
Flat Type Electrode Composite Type Electrode
Brazed
Electrode h
Copper W Joint

Electrode
Insert
Shear Burr

Localized Contact Type Electrode

Electrode h
W [Reference: Resistance Welding
Manual, p.3-12, RWMA]

Relief
Electrode
Spring-Loaded Low Inertia Electrode
Holders

[Reference: Resistance Welding Manual, p.3-10, RWMA]

Grease-Equalized Electrode Holders

[Reference: Resistance Welding Manual, p.3-10, RWMA]

Hydraulically Operated Press Welder

[Reference: Resistance Welding Manual, p.3-11, RWMA]

 Low Inertia Welding Head
Relaxed Diaphragm Compressed Partially Compressed
Air Inlet
Welding- Diaphragm Diaphragm
Welding Head Current Welding- Welding-
Switch Current Current
(Open) Switch Switch
Outer Shaft Air Inlet (Closed) (Closed)
Piston
Cylinder

Spring (Under Initial Partially

Inner Shaft Fully
Compression) Compressed Spring
Compressed Spring
Workpieces Upper Electrode Workpieces Workpieces

Lower Electrode

(a) Welding head in open (b) Welding head in position (c) Welding head at instant of
position for squeezing and heating projection collapse and
projection start of
nugget
formation
[Reference: Metals Handbook Volume 6, p.503-524, ASM]
 Punch and Die Set Design for
Mild Steel Sheet
A Punch Insert
Plug Fit Punch
Die B
C

1/4
1-3/8

1-3/8
A
1/4

B B Die Insert F
H
Plug Fit
[Reference: Recommended practice for resistance welding, AWS
Document C1.1-66, AWS, 1966]
 Punch Shapes Used for Various
Thicknesses
(a) (c)

(b) (d)

[Reference: Resistance Welding Manual, p.3-3, RWMA]