Projection Welding - Advantages and Disadvantages?

Projection welding is a type of welding that uses projection equipment to weld parts together. Projection welding can be done on ferrous metals, non-ferrous metals, and some plastic materials.

Advantages of Projection Welding:

1. Projection welding is that it produces seamless joints where no gaps are present between the pieces. 
2. It is a very accurate process and produces high-quality joints.
3. It has a high strength-to-weight ratio.
4. It is easier to weld small items like sheet metal, pipe, and bar stock.
5. The design also makes cleaning the welds very easy since they don't need to be ground off after each pass through the grinding wheel.
6. It is a Cost-effective process.
7. Less time-consuming than other types of welding processes such as gas tungsten arc or MIG welding.
8. It also produces higher quality results due to its ability to produce an even and clean weld bead with better penetration and less distortion on the base material.
9. Resulting in greater stability and less susceptibility to distortion and cracking than conventional butt-welding techniques.

Disadvantages of Projection welding:

1. High cost due to a large amount of energy required to perform this type of welding.
2. It has a tendency to cause flash burns which may require re-welding due to excessive heat generated by overheating or inadequate shielding gas supply.
3. It requires a certain level of skill and training. 
4. There can be problems with contamination during the process as well as leaks which can lead to contamination in other parts of the welded assembly. 
5. Projection welding is not suitable for all types of materials. It requires special equipment, which is expensive and can be difficult to handle with little practice.
6. Projection welding tends to produce heat-affected zones at the edge of the welded area.
7. Projection welding restricts their application to flat surfaces only (although there are some exceptions).