Projection Welding Electrodes

Electrodes for Stud and Nut Projection Welding Applications

Projection welding electrodes provide a flat surface, often incorporating holes for locators, that deliver current and force to the part. The flat surface covers the area where the projections will be welded. When holes are present for locator pins, often used for nut welding, the pins ensure proper positioning of the nut. These electrodes are typically made of copper alloy or refractory materials and are designed to withstand high current and force, resulting in longer electrode life compared to spot welding electrodes.

Stud welding electrodes are designed for projection welding screws, bolts or pins, whether they pass through the sheet or are to be attached directly to its face. Nut welding electrodes are designed for either self-piloted or non-piloted nuts. The pilots of the non-piloted-nut electrodes are spring-loaded so they can’t interfere with the contacting of nut and sheet under welding pressure.

Weld Systems Integrators is a leading supplier of resistance projection welding electrodes, maintaining an IN-STOCK inventory FOR SALE at our Warrensville Heights, OHIO location. We carry nut and stud projection welding electrodes in common standard shapes and sizes, along with custom electrodes for special applications. Contact WSI with a part numbers or fastener size and stamping hole diameter for available inventory.

Projection Welding Electrodes | Weld Systems Integrators

Common Electrode StylesChoosing ElectrodesElectrode Brands We RepresentBenefits

Projection Welding Electrodes Nut Welding | Weld Systems Integrators

Projection Welding Electrodes Nut Weld Head | Weld Systems Integrators

Projection Welding Electrodes Nut and Stud Holder | Weld Systems Integrators

Projection Welding Electrodes Weld Pins | Weld Systems Integrators

Projection Welding Electrodes Cooling Chamber | Weld Systems Integrators

Electrodes	Heads	Holders and Adapters	Pins	Components
Backup Electrodes	GH Heads	Heavy Duty Holders	Ceramic weld pins	Body
Heavy Duty Nut Electrodes	Nut Weld Head	Electrode Holders	Coated weld pins	Cooling Chamber
Heavy Duty Stud Electrodes	Stud Weld Head	Nut & Stud PM Holders		Sleeves
Non Piloting Nut Electrodes		Tapered Adapters		Springs
Nut Electrodes
Self-Piloting Nut Electrodes
Stud Welding Electrodes
Upper Nut Electrode
Arctic Electrodes
Metric Nut Electrodes
5RW Stud Electrodes
Metric Stud Electrodes

Custom Consumables

If you don’t see what your looking for on the list provided? Weld Systems Integrators can manufacture custom resistance welding consumables, electrodes, tooling and components meet your exact resistance welding needs. We can machine custom components in a variety of sizes, shapes and weights. Please contact our knowledgeable sales and service team at 844-WSI-WELD or 216-475-5629 for immediate assistance.

How to choose the right projection welding electrodes:

When choosing projection welding electrodes, consider material, size, and shape based on the application, base metal, and desired weld quality. The electrode size should be large enough to support the part and distribute the current evenly, with the projections focusing the heat and force

Material: Copper alloys are common choices for general projection welding due to their good balance of conductivity and mechanical properties.

Size: Projection welding electrodes are typically flat and should be larger than the area of the weld to prevent heat buildup and provide support. The projection itself concentrates the heat and force, so electrode size is less critical than in spot welding.

Shape: Projection welding electrodes can be flat, rounded, or pointed, depending on the application.

Nut Welding: For nut welding, tapered electrodes are frequently used, with the choice between tapered, threaded, or flanged systems depending on the removal requirements. When through-hole applications are required, locator pins with insulated sleeves are used to protect threads from weld current.

Brands we represent:

Resistance Welding Consumable BRANDS
Tuffaloy	CMW	Pacific	Worco	Centerline	Luvata

Tipaloy	RWP	Welform	ZJ Industries	Dengensha

Projection welding electrodes (fastener projection welding electrodes) are intended to carry more current and handle higher force than a typical spot welding electrode. Furthermore, stud and nut welding electrodes bring longer life and consistent performance to rocker arm and press welders. These electrodes typically have a large taper surface area which reduces seizing in the holders, making removal easier.

Features and benefits:

Accurate on center positioning of pilotless nuts provided automatically
Insulated pin and sleeve prevents pin arcing in the threads
Unit converts from welding nuts to studs in seconds by removal of pilot pin and/or welding head
Used by automotive, mass transit, farm implement, stamping and appliance manufacturers
Internal water cooling reduces heat build-up
Minimum maintenance

For pricing or immediate assistance, call at 844-WSI-WELD or 216-475-5629.

Contact Weld Systems Integrators

Weld Systems Integrators (WSI) is your complete source for standard and custom resistance welders, consumables, spare and replacement parts, and value-added services. We offer WORLDWIDE shipping from our Warrensville Heights, OH location.

CONTACT Weld Systems Integrators, or REQUEST A QUOTE on standard IN-STOCK inventory or fully custom welding equipment. To speak with a WSI team member, please give us a call at 844-WSI-WELD or 216-475-5629.

Quote Request EMail WSI

Products and Services from Weld Systems Integrators
Resistance Welders	Projection Welding	Custom Welding Automation	Supplies				Value Added Services
Resistance Welders	Projection Welding	Custom Welding Automation	Welding Consumables	Spare Parts	Welding Accessories	Available Brands	Value Added Services