Analysis of Projection Welding in Relation to the Non-Parallelism of Electrodes

Abstract

The article contains the analysis of projection welding in relation to the non-parallel location (non-parallelism) of electrodes. For a thin-walled flat element (sheet metal) with two embossed projections, the FEM calculations were conducted in relation to different angles between the electrodes. The calculation involved the use of the software SORPAS-3D. The analysis included the temperature distribution, power density, electrode displacement, volume of molten metal, nugget diameter and welding energy. The FEM results were verified experimentally by technological welding tests, destructive examination (peeling/metallographic). The experimental tests involved the application of a typical element e.g. nut with two embossed projections. The research results allow the obtainment of knowledge concerning phenomena occurring in the above-named process and unacceptable bevelling angle between electrodes.