Projection welding is a variation of resistance spot welding in which the welding current is concentrated at small raised projections – embossments – formed into one of the parts during stamping. When the electrodes clamp the assembly and current flows, the projections offer high localized resistance, generating heat preferentially at each projection point and collapsing them into the mating surface to form multiple weld nuggets simultaneously. Used extensively for attaching fasteners – nuts, bolts, and studs – to sheet metal components, for welding cross-wire assemblies, and for any application requiring multiple precisely located welds made in a single machine cycle. Available in AC and MFDC.
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