What should a good projection weld look like?

A good projection weld should exhibit good set down with little gap between the faying surfaces. The projections should be even and penetrated into both thicknesses of material. Quality specifications are available to define the tensile pull or amount of nugget required.

A1 150 collapsed Projections after weld

Sketch of a good projection weld

Reference: AWS C1.1 Recommended Practices for Resistance Welding
RWMA Manual Section 1, Chapter 3

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