Projection Welding – When Bumps Bond

Components for projection welding. Precisely manufactured, quickly available and tailored to your production. For connections where precision comes from form.

Wechselelektrode für das Buckelschweißen

Welding Method

Projection Welding: Process, Advantages and Application Areas

In projection welding, workpieces are joined via pre-formed raised sections called projections. The components are clamped between electrodes and subjected to pressure. The current is concentrated at the projections, where resistance is highest. This creates heat, melts the projections and bonds the surfaces under force.

The method offers reliable results and allows multiple welds in one operation. It is commonly used in mechanical engineering for sheet metal, grids, welded nuts and studs.

Product Overview

  • Replaceable electrode for projection welding

    Replaceable Electrodes

    Replaceable electrodes conduct both current and contact force directly into the joint area, ensuring stable electrical contact. Available in WIRBALIT® HF/N/G (CuCr1Zr).

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  • Centering pin for projection welding

    Centering and Positioning Pins

    Centering and positioning pins precisely align components during projection welding and ensure repeatable positioning. Available in silicon nitride (Si₃N₄), zirconia (ZrO₂, full ceramic), or steel with ceramic coating.

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  • Connection Cables

    Connection cables transfer welding current with minimal loss from the power source to the welding gun. Available as air- or water-cooled versions made of Cu-ETP or oxygen-free copper (OFC).

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  • Shunt straps for welding systems

    Shunt Straps

    Shunt straps conduct welding current between electrode arms and the gun while compensating for movement during the process. Made of stacked copper laminations, available in standard dimensions or as custom designs.

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We keep your production running

  • With one of the largest inventories in Europe, we supply standard formats without delay. Custom solutions are implemented flexibly and at short notice thanks to in-house development and lean structures.

  • As an active member of the German Welding Society (DVS), we contribute our practical experience directly to standards and guidelines. This results in solutions that meet and shape the state of the art.

  • In close cooperation with you, we assess requirements, identify optimization potentials, , and implement targeted measures to increase the efficiency of your processes. For us, consulting as an integral part of manufacturing.

  • Where standards are not sufficient, we manufacture components based on drawings, samples or as custom developments. Every solution is tailored exactly to your production and supports its long-term efficiency.

  • All production phases are embedded in a structured inspection system that identifies and documents deviations at an early stage. For demanding applications, we inspect components individually based on your specifications.

  • Our decades of experience in welding technology are reflected in every component. We combine practical know-how with technical depth to deliver reliable and durable results.

SVS Capabilities

Need advice? Our experts assist you in choosing the optimal solution for your production.

Kai Kleinevoß Portrait Head of Sales Wirbalit® SVS Schweißtechnik

Kai Kleinevoß

Head of Sales Wirbalit®
kleinevoss@svs-schweisstechnik.de
+49 208 99 328 15