Method of resistance projection welding sensors

A method for resistance projecting welding the components of a current sensor is disclosed. The method comprises the steps of providing a first blade having a projection extending outward and a first conductor, supporting the first blade and the first conductor, positioning the first blade adjacent to the first conductor so that the projection of the first blade contacts an opposed surface on the first conductor defining a contact area, supplying an electrical current of a predetermined magnitude and predetermined duration to the first blade and the first conductor to create a weld at the contact area and continually applying a compressing force of a predetermined magnitude to the first blade throughout the supplying step to resistance projection weld the first blade and the first conductor at the contact area. The present method overcomes the drawbacks of the prior art by providing an alternative method to fabricate current sensors. Finally, the method reduces part production costs and increases part reliability while obtaining desired production rates.