Resistance projection welding (RPW) is a variation of resistance welding in which current flow is concentrated at the contact surfaces of interest by an embossed, cold headed, or machined projection. The projection(s) effectively localize the current, forcing the parts to heat predominately at the mating surfaces. This rapid interfacial heating allows for the application of resistance projection welding across a wide range of applications not feasible by conventional resistance spot welding.

The projection is designed to localize current flow at the contact surfaces where the joint is desired. This focuses heat at the mating surfaces of the pieces and minimizes bulk heating of the parts. This rapid thermal cycle allows for precision joining of detailed parts, joining of metallurgically challenging materials, and formation of multiple welds simultaneously. While the projection usually collapses early in the weld cycle, the localized heating raises the material resistance locally and promotes further heating and finally weld development at the initial contact point. The process can be developed to produce a recast fusion type weld or a solid state weld depending of the application.

Because the formation of the weld is highly localized, the process is considerably more energy efficient than other resistance welding processes.

Share this:

Latest News

EWI Welcomes New Member Cincinnati Fan
We are pleased to announce that Cincinnati Fan of Mason,…
Read more...
EWI’s Additive Manufacturing Consortium
In 2010, EWI established the Additive Manufacturing Consortium (AMC) as…
Read more...
New Paper – Pulsed Gas Metal Arc Welding of Copper-nickel Pipe Joints
Copper-nickel alloys are often used in shipbuilding for applications such…
Read more...
Arconic is New EWI Member
We are pleased to welcome Arconic to EWI membership. The…
Read more...
EWI Appoints Rob Walter as New CFO
EWI is pleased to announce the appointment of Rob Walter as the new CFO and Vice President of Administrative Services.EWI is pleased to announce the appointment of Rob Walter…
Read more...
3D Vision-guided Robotics for Industrial Applications — New Paper
Advanced robot-based object detection, recognition, and gripping technologies have seen…
Read more...
New Guide: NDE Breakthroughs that Ensure System Integrity and Lifetime Quality
Advanced nondestructive evaluation (NDE) allow manufacturers to more effectively comply…
Read more...
South Korean Delegation Visits EWI, Signs Collaboration Agreement
On Wednesday, June 7, EWI hosted a contingent from the Ulsan Metropolitan City, Republic of Korea, to sign a collaboration agreement to pursue R&D activities for the mutual benefit of both partiesOn Wednesday, June 7, EWI hosted a contingent from the…
Read more...