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Projections (low thermal mass islands) are one method of insuring proper heat balance in difficult spot welding applications when there exists a 5:1 size difference between the parts to be welded. By providing a projection on the surface of one of the workpieces, weld current and force can be focused into the small area of the projection to produce heat at the desired weld location.
Projection welding can extend electrode life by increasing the electrode contact area and decreasing the current density at the surface of the electrode. Projection welding is effective even if the weldments are thick or when using conductive materials.
Projection welding can be used, for example, in hermetic seam sealing micro-electronic packages like TO cans. A projection is usually placed on the case and a high current pulse allows for simultaneous collapse around the entire length of the projection. In a controlled environment, it is possible to keep out moisture, oxygen, and any other potentially harmful elements for the electronics.
Lasers can also be used to hermetically seal electronic, RF and microwave packages. The package lid is placed on top of the base and the laser first tacks the lid into place, then scans around the entire outside edge of the package to seal in the internal components. This type of welding is typically done inside a glovebox with a controlled atmostphere.
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