I am trying to projection weld a 10mm stud with a continuous ring projection to 1008/1010 material .120" thick. I am having a difficult time getting a consistent weld. Currently I am getting virtually no penetration into the parent material. The RWMA has no recommendations. Does anyone have experince with the continuous ring projection? I have a 200Kva transformer at max current tap. 90% current 18 cycles Ohma cylinder set at 95 psi If I vary the parameters up or down, I either get expulsion or the weld fails the torque requirements.

-- Brian Plew (b.plew@tmpind.com), January 15, 2003

Answers

if you will send me an address, I will send you a copy of the study on ring projection welding done by EWI.

-- tom mitchell (info@atekcorp.com), January 23, 2003.

Hello Brian,

Another source of info could be the Ohio Nut and Bolt website www.on-b.com Look at the low carbon weld nut setup data at http://www.on-b.com/product/weldata/wd-lc-nu.htm

I think you will find your problem is the transformer capacity. I cannot calculate your current and weld force without further info, but I'll bet you are nowhere near the 3000 pound, 50,000 amp settings that you probably require. You need to do this in 16 cycles or less, and NEVER use impulse welding, it must be done in one pulse of current.

David Bacon

-- David Bacon (dbacon@updatetechnology.com), March 17, 2003.

I just built a machine to do this same process. The 10mm stud has a full ring projection & it has to pass leak testing & push-out testing. The 200 kva transformer is correct, but what is your electrode force? You will need an OHMA air over oil cylinder with a 32:1 ration at about 70psi (2300 lbs of force). I set this up with a medar 3005 & I have the parameters from the system.

jlosey@marathonweldgroup.com

Jeff Losey

-- Jeff Losey (jlosey@marathonweldgroup.com), June 16, 2004.