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NBC-9134 HY-PAK® Welding General Applications

 

HY-PAK® Welding:

In response to the needs of many users of the resistance welding process, Newcor designed, developed and patented the HY-PAK® Welding process. This process allows for the creation of a solid state weld in a short duration of time with less force than a typical resistance weld.

The HY-PAK® Welding process combines a high energy, short duration weld pulse with a low inertia, fast follow-up weld electrode. This process allows for welding with much less force than typically required. The combined features of the process allow for the welding of materials and parts that otherwise would be very difficult to weld.

  

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The thin-gauge stainless steel honeycomb is welded to the much heavier backing plate using HY-PAK® Welding at more than two welds per second without danger of crushing or melting the lighter structure.


Design Features:

  • HY-PAK® Welding is low cost.
  • Show surface welding without rework.
  • Minimal disruption of protective coatings.
  • Ability to weld through most coatings.
  • Minimal water cooling.
  • Improved part quality.
  • High Speed (140 welds/min).
  • Minimal coating pickup on electrodes.
  

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This filler neck support is HY-PAK® Welded onto fuel tank exterior.
 

Application:

  • Aircraft : Welding stainless steel honeycomb backing plates for aircraft engine seals.
  • Electronics : Welding high wattage transistor casings creating hermetically sealed containers 0.25 mm thick.
  • Container : Welding handles to manufactured prepainted pails.
  • Pressurized Containers : Charging and sealing pressurized containers.
  • Dissimilar Metals: Welding copper lugs to steel.
  • Automotive : HY-PAK ® Hem Welding; strut charge & seal welding.
  

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A soft steel ball is HY-PAK® Welded to hermetically seal a pierced hole in the vessel wall.


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Mounting bolt can be welded to the interior of painted cabinets using HY-PAK® Welding with no visible damage to the finish.
 

Materials:

The material can be a coated or uncoated, light-gauge, weldable material ideally no more than .048 inches (1.2 mm) thick. Material successfully welded include but are not limited to.

  
  • Aluminum
  • Copper Alloys
  • Dorrlform®
  • Galvanized
  • Steel Pre-Paints
  • Steel
  • Steel Alloys
  • Terne Plate
 

Part Configuration:

Weld projections in thin materials must be of sufficient column strength to withstand the welding force and the part or work piece containing the projection must be designed for fast follow-up during the welding process.

  

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Standard Projection Design
 

Reasons for Use:

When properly applied, HY-PAK® Welding can provide these advantages.

  • The process causes a minimal disruption of protective coatings. this is especially important where the integrity of corrosion protection by the coating is critical to the component's environment.
  • The process rarely causes marking of show surfaces in either coated or uncoated materials. Seldom is surface finishing required even on the most visible of surfaces.
  • Weld nuggets with or without adhesives or sealers.
  • Reduces the requirements of adhesive, toggle locking or riveting operations.

 

  

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This pail handle bracket is HY-PAK® Welded through prepainted material.
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