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HY-PAK® Solutions   

The Problem

Resistance projection welding is a process in which the welding heat is localized at a predetermined point established by the design of the part. Electrical current flow is concentrated in one or more projections in one of the parts, and heat is generated, Normally, the projection heats to a plastic temperature at which point it collapses due to the electrode force at approximately 20 to 30 percent of the total weld time. Heat continues to be generated in both parts until sufficient nugget growth is realized and then the current is terminated.

Projection welding is a rather tolerant process, permitting parameter variations to occur without seriously effecting the integrity of the weld. How-ever, for light materials, the process becomes more critical, As projections collapse under the initial die impact of force, heat is dissipated into the tooling instead of in the projection and it is exaggerated even more by the heating and cooling of the sinusoidal current in AC power. For coated materials this has presented additional problems with coating material pick-up on dies, the surface coating being burned away, and higher currents being required.

HY-PAK® is used to produce a structural weld between inner and outer hood panels, maintaining dimensional characteristics, without damage to material coatings.

The Solution - HY-PAK®

A Newcor welding process, that generates a high magnitude of heat, for a short duration, in a unidirectional pulse with a rapid electrode follow-up. The basic design of the HY-PAK® unit includes a single phase 460 volt power supply. The weld time is determined by the firing point on the voltage wave, always kept to less than 90 degrees. A shift register circuit determines which SCR in the primary electronic switch is to be turned on so alternate polarity is obtained on each subsequent weld. A special welding transformer is designed for a higher secondary voltage than normal, and the primary/secondary coil arrangement insures the lowest possible mutual reactance.

The important mechanical feature is the low inertia current carrying weld head. It is capable of carrying the 40,000 to 60,000 amp weld pulse and has the mechanical follow-up characteristics to set down the projection in less than one millisecond. HY-PAK® welding uses standard weld schedule setups and therefore does not require special training. It is on operator-friendly process.

Hoods, doors, decks, and endgates benefit from HY-PAK® structural welds. Hoods, doors, decks, and endgates benefit from HY-PAK® structural welds.

HY-PAK® hem welding shows tab successfully welded in place.

Advantage & Benefits

• Show Surfaces Welding
  Hem Welding Without Surface Rework.
• Low cost
  High Equipment Reliability.
• High Speed
  140 Welds Per Minute.
• Improved Part Quality
  Dimensional Variation Reduced.
• Minimal Disruption of Protective Coatings
  Not Affecting Corrosion Protection.
• Ability to Weld Through Most Coatings
• Minimal Coating Pick-up on Electrodes
  Process Speed Minimizes Heat.
  Coatings Against Electrodes Do Not Melt.
• Minimal Water Cooling Required
  Less Heat Produced.
• HY-PAK is a Resistance Welding Process
  Standard Set-Ups and Operation.
• Does Not Require Special Training of Maintenance or Operators
  Process Uses The Fundamentals of Resistance Welding.
• Does Not Crush lightweight Materials
  Welding Forces Are Low.
• No Dangerous Capacitors or High Voltage
  Process Is Very Safe.

Modular HY-PAK® unit design provides easy integration into existing, or new lines.

Light gauge coated sheet fuel sender brackets are HY-PAK® welded with no break down of the coating.

Process Requirements

• What are some of the Process Requirements

• Light Gauge Material (0.048-in. max.)

• Sharp Projections Needed When Welding Non-Conductive Coatings.

• Part with Projection Must Be Designed for Fast Follow-up.

• Weld Projections Must Be of Sufficient Column Strength to Withstand Welding Force.

• Projection Profiles Must Be Maintained for Optimum Weld Nugget Development.

• Series or Indirect Welding is Needed for Welding Non-Conductive Coatings.

What Types of Material can be Welded using the HY-PAK® Process?

Applications

Hemming
Inner and outer sheet metal panels are often hemmed for cosmetic reasons. A structural bond is typically required to maintain the relative positions of the two panels after hemming. HY-PAK® welds strategically placed around the perimeter of the panel eliminates the need for spot induction curing of commonly used structural adhesives prior to final curing in paint ovens. This process eliminates inner panel movement during storage and shipping racks or paint oven baking, thus improving part quality and reducing warranty claims.

Coated Materials
Terne coated baffles and filler neck supports are HY-PAK® welded to terne coated automotive gas tank halves without coating disruption. Terne coated baffles and filler neck supports are HY-PAK® welded to terne coated automotive gas tank halves without coating disruption.

Light Gauge Materials
Tube support brackets are HY-PAK® welded to the mounting flanges of automotive fuel tank sender brackets. Tube support brackets are HY-PAK® welded to the mounting flanges of automotive fuel tank sender brackets.

Thin gauge stainless steel aircraft engine honeycomb seals are welded to heavier backing plates with HY-PAK® without danger of crushing or melting the lighter structure seals. without danger of crushing or melting the lighter structure seals.

Who's Using it

Chrysler
HY-PAK® Welding Hems of Hoods, Doors and Tailgates.

Ford
Welding of Fuel Tanks and Sender Units.
Sealing Gas-filled Shocks. Welding of Fuel Tanks and Sender Units.
Sealing Gas-filled Shocks.

General Motors
Fuel Tank Components. Fuel Tank Components.

General Dynamics
Aircraft Engine Honeycomb Seals. Aircraft Engine Honeycomb Seals.

Active Tool
HY-PAK® Welding Hems of Utility Vehicle Liftgates. HY-PAK® Welding Hems of Utility Vehicle Liftgates.

Massiv Die Form
HY-PAK® Welding Hems of Automotive Doors. HY-PAK® Welding Hems of Automotive Doors.

Peugeot
HY-PAK® Welding Hems of Doors and Deck Lids. HY-PAK® Welding Hems of Doors and Deck Lids.

Citroen
HY-PAK® Welding Hems of Doors. HY-PAK® Welding Hems of Doors.

HY-PAK® is integrated into processing lines and replaces induction curing on automotive panels with hemmed flanges.

Truck hood using HY-PAK®