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Projection Welding
Categories  / HOME (/) / PROJECTION WELDING

QUESTIONS AND ANSWERS

Spot Welding

Projection
Welding
What type of equipment is used
Seam Welding for projection welding?
Flash Welding (/projection-welding/189-
Butt Welding what-type-of-equipment-is-
Controls &
Transformers used-for-projection-
(/controls-and-
transformers.html)
welding.html)
Projection welding traditionally has been performed using AC controls
Next
and power supplies. The welders frequently have been traditional press
Question
welders and recently xed station weld guns. both provide good
alignment and can be designed for low inertia fast follow up systems. 
Rocker arm machines are not a good choice because they apply force in
an arc and do not hold good alignment. In all cases fast follow up
All Categories  cylinders or servos are necessary for good quality.

With the advent of MFDC (Mid Frequency) controls and their accuracy
these units are a logical player in projection welding. To make them
suitable in this application, fast rise time technology has been
Popular
developed because standard MFDC has a slow current rise. Another
Subjects
 system that has shown some application for nut and stud welding is CD

electrodes (capacitive discharge welders). This technology has been around for
years. In the recent years CD has evolved into higher energy machines
(/tags/electrodes.html)
capable of nut and stud welding.

controls Welding Journal, July 2017

Reference: AWS C1.1 Recommended Practices for Resistance Welding
(/tags/controls.html)
RWMA Manual Section 3
Tu aloy Product Inc. Catalog
fundamentals CMW Inc. Resistance Welding Products Catalog
(/tags/fundamentals.html)
AC | CD | MFDC Controls | follow up | low inertia |
fast follow up |
design
low ineretia machines (/tags/low-ineretia-machines.html)
(/tags/design.html)
water cooled What are the advantages of
(/tags/water-
cooled.html) resistance brazing?
material
(/tags/material.html)
(/projection-welding/34-low-
force inertia-machines/188-what-
(/tags/force.html)
inverter are-the-advantages-of-
(/tags/inverter.html)
mid frequency resistance-brazing.html)
current A resistance braze o ers a few advantages over traditional spot
(/tags/mid- welding:
frequency-
current.html) First it allows the joining of materials that otherwise cannot be
Mid Freq resistance welded. Generally they are very conductive materials and
(/tags/mid- hard to get hot enough to form a weld nugget. Coppers and brasses
freq.html) would be an example of these.
MFDC
Secondly a resistance braze can be performed at a lower temperature
(/tags/mfdc.html)
than a spot weld. We do not have to bring the work piece up to near its
fast follow up
melting point. We only need to bring the braze shim to its melting point
(/tags/fast-
which is much lower. This means the work piece can preserve some or
follow-up.html)
all of its mechanical properties. Post heat treatment may not be
heat balancing
necessary.
(/tags/heat-
balancing.html) The third advantage is that we can control the area of heat application
midfrequency to a small area of the part. We are only heating to a modest
(/tags/midfrequency.html)
temperature and we can protect other areas if desired with cooling. The
midfreq rest of the part stays strong for the end application.
(/tags/midfreq.html)
 SCR Reference: CMW Products Inc. Catalog
(/tags/scr.html)                  Tu aloy Products Catalog
contactors                  RWMA, Resistance Welding Manual. Section 1, Chapter 6
(/tags/contactors.html)
Resistance Brazing | brazing |
current
risistance brazing advantages (/tags/risistance-brazing-
(/tags/current.html) advantages.html)
MFDC Controls
(/tags/mfdc-
controls.html)
How do resistance brazing
projection
design
schedules vary from spot
(/tags/projection-
design.html)
welds? (/projection-
welding/34-low-inertia-
machines/187-how-do-
resistance-brazing-schedules-
vary-from-spot-welds.html)
The goal of a resistance brazing schedule is to bring a thin sheet of
braze alloy to its melting point and form a llet around the periphery of
the part being joined. The squeeze cycle is basically the same as in spot
welding – put the parts under the desired holding force. The o cycle is
the same – cool and resolidify the braze material. What varies is the
weld or heating portion of the cycle. Spot welds generally take a few
cycles, or milliseconds. The time is generally less than a second. A
resistance braze frequently will take several seconds up to many. It
depends upon the size of the part and how conductive the material is.

Resistance Brazing | brazing | low force holders |

low force adjustable holders (/tags/low-force-adjustable-
holders.html)

READ MORE ... (/PROJECTION-WELDING/34-LOW-INERTIA-MACHINES/187-

HOW-DO-RESISTANCE-BRAZING-SCHEDULES-VARY-FROM-SPOT-WELDS.HTML)

How much force is used for

resistance brazing?
(/projection-welding/34-low-
inertia-machines/186-how-
much-force-is-used-for-
resistance-brazing.html)
In resistance brazing we are not spot welding but we still are passing
modest currents so an adequate force is necessary to avoid arcing. The
main goal of the force is to hold the parts together for current ow and
avoid arcing so the braze alloy is not arced out of the joint. This is
usually a modest force developed by trial with set up parts. Joule
Heating H= I2rt will then generate the energy necessary for the braze
material to melt. When molten braze metal is visible in the let the
current can be turned o and allowed to cool under pressure until
solidi ed. Then the electrode can open and the part is ready to be
ejected or removed. The temperature that the part reached at the joint
is lower than it would have been if spot welded but it will be hot so
caution is required.

Resistance Brazing | brazing | low inertia holders |

low force holders |
low force adjustable holders (/tags/low-force-adjustable-
holders.html)

READ MORE ... (/PROJECTION-WELDING/34-LOW-INERTIA-MACHINES/186-

HOW-MUCH-FORCE-IS-USED-FOR-RESISTANCE-BRAZING.HTML)

What electrodes are used for

resistance brazing?
(/projection-welding/33-fast-
follow-up-holders/185-what-
electrodes-are-used-for-
resistance-brazing.html)
Resistance brazing is not spot welding so the electrode face geometry
does not have to concentrate the heat into a small area. Frequently the
electrode face is machined to conform to the surface that it is in contact
with. Frequently the electrode will contact the entire work piece surface.
In some cases the electrode faces is milled out so the work piece can be
nested into the face of the electrode in order to insure proper part
 placement and alignment. A small vacuum is sometimes pulled through
the center of the electrode to hold the part in place before the electrode
closes. This is very common for small part brazing.

Resistance Brazing | low inertia holders |

refractory faced electrodes (/tags/refractory-faced-electrodes.html)

READ MORE ... (/PROJECTION-WELDING/33-FAST-FOLLOW-UP-HOLDERS/185-

WHAT-ELECTRODES-ARE-USED-FOR-RESISTANCE-BRAZING.HTML)

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