Abstract: The invention relates to projection welding of a second metal sheet above a first metal sheet (50), wherein the first metal sheet is of a non-ferrous metal or metal alloy having as main component aluminum or magnesium, wherein the first metal sheet comprises an elongate projection that locally extends above the main upper surface of the first metal sheet to come into contact with the main lower surface of the second metal sheet, wherein the projection comprises an upper surface having a convex first section (65) with a first radius (R1) that defines in its middle the top height of the upper surface with respect to the main upper surface of the first metal sheet, and a convex second section (64) with a second radius (R2) along both elongate sides that merge into the first section, wherein the first radius is larger than the second radius.

Abstract: The invention relates to projection welding of a second metal sheet above a first metal sheet (50), wherein the first metal sheet is of a non-ferrous metal or metal alloy having as main component aluminum or magnesium, wherein the first metal sheet comprises an elongate projection that locally extends above the main upper surface of the first metal sheet to come into contact with the main lower surface of the second metal sheet, wherein the projection comprises an upper surface having a convex first section (65) with a first radius (R1) that defines in its middle the top height of the upper surface with respect to the main upper surface of the first metal sheet, and a convex second section (64) with a second radius (R2) along both elongate sides that merge into the first section, wherein the first radius is larger than the second radius.

Abstract: A method for manufacturing a projection weld connection between at least two parts of a workpiece, where the workpiece remains blemish free, comprising automated real-time verification of the quality of the individual weld, without use of destructive testing by analysis of data from a force sensor is disclosed. Measurements of the quality of each weld can be calculated, and real-time measurements and calculations can be used to verification of the structural integrity of the projection in the workpiece before the welding current is applied in order to avoid further damage to the workpiece. The method may be implemented in a system comprising, among other features, a displacement sensor.

Abstract: The present invention generally relates to a method for manufacturing a projection weld connection between at least two parts of a workpiece, whereby said workpiece remains blemish free, whereby said method is characterized by the fact that it comprises automated real-time verification of the quality of the individual weld, without the use of destructive testing. The invention also relates to a system implementing said method comprising, among other features, a force sensor and a displacement sensor.