Projection Welding

Questions and Answers

Cracks appearing in the parent material around the weld nugget can be caused by several issues. They are:

High Weld Force – can fracture the parent material with excessive forging action.
Insufficient Cooling – Over heating can cause excessive stresses from expansion and contraction along with the forging action.
Metallurgy of Material Welded – Some materials become brittle at the temperatures experienced in resistance welding.

Internal cracks in the weld nugget can lead to decreased strength and need to be prevented or reduced.

Surface expulsion is caused when the part surface heats up. So anything which would cause this, could be a reason. The appearance is similar to interface expulsion. In this case we are looking for conditions which cause the contact surface heat to be high.

Surface Expulsion Electrode Sticking


Expulsion of molten particles from between the two sheets of metal being welded can be caused by several items. All are related to causing excessive heat between the two work pieces or not containing the weld nugget during welding.

 Expulsion at Weld Interface

Force is one of the main inputs of the weld machine in the form of pressure exerted by the electrodes on the work piece. The main function of this force is to contain the weld by holding the work pieces together tightly during the welding operation. Stronger work piece materials require higher welding forces than weaker work pieces. With adequate force the contact resistance between the electrode and part is minimized and more energy is transmitted into the part to heat the interface between the two sheets being welded.

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