At Tec Option, we are pleased to offer the highest quality welding equipment in the industry. With over 20 years of experience, we have an in-depth understanding of the welding process and its uses in various applications and industries. Our projection welding equipment is second to none, with a variety of designs and customizations available to ensure the most accurate and durable welds.

Projection welding is a form of resistance welding which uses pressure and electrical current to join two or more metal parts that have been designed to meet at one or more specific points with the maximum amount of contact. This allows for more efficient welding with less energy and greater weld strength.

This type of weld not only adheres two pieces of steel together, but also can weld a nut, threaded stud, or projection to an assembly.

Projection Welding

Advantages of Projection Welding

Automated Welding When projection welding, the component parts must be specifically manufactured with dimples or projections, in order to ensure that they fit together and maximize contact between the parts. The welding process is tailored to the material and component’s intended use.

The welder applies force and electrical current through the welding machine at one point of contact. The pressure, current strength, and amount of time that the current is applied will vary depending on the material and processing specifications.

Projection welding offers a wide range of benefits over more traditional welding methods, including:

  • Increased production. The process allows for more than one weld to be completed at one time, thereby increasing production output.
  • Extended lifetime. Projection welds have a longer life expectancy than spot welds, as it requires less heat and pressure during the welding process.
  • Versatility. Projection welding equipment is easy to adjust to different parameters, so it can be used for a wide variety of parts and components.
  • Ease of use. Projection welding uses highly automated equipment and multiple welds can be handled at one time.
  • Clean finish. The point of contact is on one side and the pressure is minimized, so projection welding allows for reduced surface imperfections at the welded joint and results in a smoother finish.
  • Closer welds. Projection welding equipment allows for welds that are closer spaced, because there is less pressure applied to each joint.

Differences Between Spot Welding and Projection Welding

Spot welding and projection welding have some similarities, but they are typically used in different situations.

  • Spot welding is the most common form of welding and differs from projection welding in a number of ways. This process is typically used to connect large components or sheets of metal using metal currents along the joint. The current is directed at one point—as opposed to the multiple projections found with projection welding—and requires more current and pressure. Spot welding is particularly useful for corners and thin materials.
  • Projection welding is more useful for thick metal materials and products that require an exceptionally strong weld, since less heat and pressure during the welding process yield a stronger joint. Projection welds are also less visible than spot welds, allowing for a more aesthetically pleasing finished appearance. Projection welds can also used to weld a nut, stud, or projection on steel and is used in many automotive assemblies.

Projection Welding Applications

Drawn Arc Welding Automation
Due to its low energy usage, strong welds, and exceptional versatility, projection welding is useful for a wide range of applications, including:

  • Automotive. Projection welding is used to weld connectors such as screws, nuts, and bolts to flat sheets.
  • Consumer goods. Manufacturers use projection welding to secure fasteners in consumer goods such as fans and fan covers, furniture, and household appliances.
  • Construction. Projection welding produces products used in construction, such as hollow metal doors, heavy plates, and metal panels.
  • Mechanical. Projection welding secures fasteners to components and covers in mechanical equipment and joins crossed wires and bars. It is particularly useful in industrial settings where the weld must be able to withstand a great deal of pressure.
  • Semiconductors. The close fit of projection welds is ideal for hermetically sealed semiconductor equipment to prevent the intrusion of air and other gases that could compromise the equipment’s operational capacity.

Projection Welding Services from Tec-Option

Tec-Option is pleased to be a premier manufacturer of top quality weld machines and automated welding systems for a variety of industries. Our experienced engineers and specialists are happy to help you engineer, design, and assemble the perfect weld machine for your application. You can rely on Tec-Option for highly efficient and cost-effective equipment that will produce exceptional quality products in a timely fashion.

For more information on our superior welding equipment, contact us today!