Projection welding utilizes localized heat generated by a high-voltage electrical current passing through copper electrodes to fuse two metal pieces together. The electrode or cap tip directs the current to the precise weld location, creating a projection or raised bump on one side of the joint. The electrode’s weld face focuses the heat for a strong, consistent bond.

One of the key advantages of projection welding is its fast processing speed and energy efficiency. Unlike other welding methods that require gas or additional materials, projection welding relies solely on electricity, making it a cost-effective and environmentally friendly solution.

This welding process can be performed manually using a welding machine or automated with robotic systems. Automation enhances precision and efficiency, eliminating the need for a specialist to hold a welding torch while wearing cumbersome protective gear.