Resistance projection welding, or RPW, is a form of resistance welding where the electricity, force, and time are concentrated on raised segments (or projections) to join items together. This process has the benefit of forcing the welds to occur in very specific and tiny locations, and minimizing the dissipation of heat to the rest of the metal sheets.
Resistance projection welding can be found in the automotive industry, where screw-fastener parts such as nuts and studs (see above) are joined to metal sheet components. It is also found in cross wire and bar welding, or in day to day products such as shopping carts. As with resistance spot welding, the difficulties in welding aluminum, high strength steels and coated steels has encouraged Huys to look for simple solutions. Some of our answers to these challenges include ceramic pins, modular weld heads, SORPAS® weld simulations, and upside-down nut detecting electrodes.