13/10/2017 EWI Resistance Projection Welding

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Resistance Projection Welding

Resistance projection welding (RPW) is a variation of resistance welding in which current ow is concentrated at the contact
surfaces of interest by an embossed, cold headed, or machined projection. The projection(s) effectively localize the current,
forcing the parts to heat predominately at the mating surfaces. This rapid interfacial heating allows for the application of
resistance projection welding across a wide range of applications not feasible by conventional resistance spot welding.
The projection is designed to localize current ow at the contact surfaces where the joint is desired. This focuses heat at the
mating surfaces of the pieces and minimizes bulk heating of the parts. This rapid thermal cycle allows for precision joining of
detailed parts, joining of metallurgically challenging materials, and formation of multiple welds simultaneously. While the
projection usually collapses early in the weld cycle, the localized heating raises the material resistance locally and promotes
further heating and nally weld development at the initial contact point. The process can be developed to produce a recast fusion
type weld or a solid state weld depending of the application.
Because the formation of the weld is highly localized, the process is considerably more energy e cient than other resistance
welding processes.

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