An Introduction to Projection Weld Stud

Posted on Feb 4, 2021

Projection Weld Stud

Through the electro-thermal process, fasteners like projection weld studs, screws are unique parts that are manufactured to be fused to other components, creating a strong and permanent connection.

What Are Stud Welding and Projection Weld Stud?

Stud welding is the process of utilizing a projection welding machine to join the circular parts to flat pieces through the welding arc and the proper amount of pressing force. Through the electro-thermal process, fasteners like projection weld studs, screws are unique parts that are manufactured to be fused to other components, creating a strong and permanent connection. Depending on the applications and products, there are a large variety of spot weld studs and tab weld studs can be chosen today, optimizing the stud welding process and product quality for different needs.

When it comes to projection welding machines, it is one type of resistance welding machine with the design and shape of unique components that are designed to make discreet individual point contacts, focusing the electric current on the surface of materials, melting and fusing the parts together. Just like other kinds of electric resistance welding machines, projection welding machines for projection weld studs rely on the high heat generated from electrical resistance and also the electrode forces,  which are regulated properly toward the weld joints. 

Commonly used for producing plate products, cross-wires, and many more welding applications that require material intersection welding. Projection welding machines are popular in metalworking environments. The welding equipment can achieve multiple welds at once if employing more projections in the structure. 

Although very similar to classic spot welding machines, the electrodes of projection weld stud machines are not responsible for concentrating the heat. The high heat is focused through the special arrangement or the unique projection parts, making the equipment greatly efficient and effective welding tools. The alignment and projection consistency are important factors that should be critically checked and controlled to ensure the smoothness of the projection weld stud production and the weld quality.

Projection Welding Process

As mentioned, the projection weld stud machine relies on special, small projection parts to create discreet individual point contacts. As a result, the electric current can be concentrated in the spots. These projection parts are formed on one single side of the components to be joined, which mostly come in the circular type, round dimple type, elongated ridge type, or the extending corners of the weld nuts. 

Some special arrangements in the structure of the projection welding machine include the fully customized projection welds having two round wires mounted together at 90 degrees, forming a contacting point. When the mating parts are positioned together, the projection parts focus the current flow, which is stably supplied by the projection welder, then generating the weld heat with the high temperature up to 4000° in the working area. 

As the projections become hot, the special parts will collapse as the weld nugget forms. Several weld nuggets can hold the metal parts together, creating a powerful, firm connection after cooling. In the metal fabrication applications like cross wire joining, the efficient welds can be achieved at once as in fencing, or the operator can also complete one weld per crossing position.

The projection parts in these projection welding machines should be critically and specifically designed and machined with dimples or other features to ensure the ideal accommodation, ensuring the effective contact between the metal parts to be welded. 

The projection weld stud processes can be tailored to meet the individual needs in relation to material types and components that are intended for use. The welding pressure as well as the weld current, and also the length of the weld time should all be considered carefully depending on the usage and productional specifications.

:: Read more: Projection Welding is the Boss of Embossments

Why Do You Need a Projection Weld Stud Machine?

Projection weld stud machines offer numerous benefits when compared to classic resistance welding machine types. First of all, the projection welding process provides the user excellent heat balance in many challenging applications where the welds cannot be achieved by spot welding. For instance, if the metal parts to be welded have a 5:1 size difference, the applications should employ a projection welding machine. 

Also, the projection weld stud machine is able to concentrate the weld current and pressure onto an extremely tiny area on one of the part’s surfaces, making the process precise and efficient. Projection welding is, in general, more effective and reliable even when the welds are relatively thick or if using conductive materials.

The projection welding machine typically extends the electrode life, since the contact area of the electrodes increases and the density level of the weld current decreases.
This also allows the projection welding machines to have a longer life expectancy than other resistance welding machine models. 

Last but not least, the projection weld stud welder permits multiple welds to be finished at once, in a single welding tool. The feature greatly enhances the production output and efficiency, making the equipment an ideal investment for high volume, repeated production. Since the contacting weld point is only on one side with less pressure in the welding process, the projection welder is not only fast but also offers high quality, cleaner and smoother surface finish.

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