What is the main advantage of projection welding?

Projection welding offers a unique advantage by reducing the contact area between the two parts being joined. The process utilizes protrusions or "projections" on one or both of the components, which are designed to focus the welding current and heat into these specific areas. This focused energy leads to a decrease in the overall heat affected zone, resulting in a more efficient weld with less thermal distortion. By minimizing the contact surface area, projection welding also allows for greater control over the weld quality, as it ensures that the energy is concentrated where it is most needed.

Other methods of welding might require extensive surface areas to achieve adequate welds, which can lead to issues such as overheating and distortion in larger or more complex assemblies. Additionally, the reduced contact area helps to streamline the process, promoting faster production rates while maintaining the integrity of the joint.