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Projection welding is a resistance welding process that concentrates weld current and force at a specifically designed projection on one of the workpieces. The projection focuses heat generation at the desired weld location and collapses during welding to form the joint.
Projection welding is particularly useful when proper heat balance is difficult to achieve, including applications where there is a significant difference in the size or mass of the parts being welded. It can also be effective for thick weldments and highly conductive materials.
A projection is formed on the surface of one of the parts to be joined. When the parts are brought together under force, the projection creates a localized area of high electrical resistance. Weld current and force are concentrated at this point, generating the heat required to form the weld. As the material heats, the projection collapses and the parts are joined. Because the projection determines where current is concentrated, part and projection design are important elements of the welding process.
Projection welding offers several advantages for applications requiring concentrated and controlled heat generation:
Projection welding can increase electrode life because the larger electrode contact area reduces current density at the electrode surface.
Projection welding can be used to hermetically seal microelectronic packages such as TO cans. A continuous projection is typically incorporated into the case or cap to define the sealing area.
During welding, a high-current pulse causes the projection to collapse around its entire length, creating the seal. When the process is performed in a controlled environment, the sealed package can protect sensitive electronics from moisture, oxygen, and other potentially harmful environmental elements.
AMADA WELD TECH projection welding systems can use capacitive discharge (CD) welding technology to provide the high-current, short-duration energy required for projection welding applications.
Capacitive discharge power supplies store energy in capacitors and rapidly discharge that energy through the welding circuit. This rapid energy delivery is well suited to applications requiring a concentrated welding pulse, including projection cap welding and hermetic sealing.
AMADA WELD TECH projection welding solutions combine the welding power supply, weld head, tooling, and process control required for the application.
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