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Introducing Projection Nut Welding

Posted on Dec 15, 2020

Projection Nut Welding

Nut welding is essentially the welding used to attach threaded nuts to another piece of metal object. A nut welding is usually carried out by means of projection welding because the nuts may have a partial or full ring projection or multiple corner edges are formed during the process. Therefore, nut welding is also known as projection nut welding.

Projection Nut Welding Overview

Projection nut welding is a welding process that welds nuts onto designated surfaces by means of projection welding. Projection welding is a type of resistance welding. Instead of simply welding two spots on each of the flat surfaces of two metal objects, a projection is needed during the process. Two objects are welded together on one flat surface and a projection on the surface of the other object. In a projection nut welding process, a nut is welded onto a surface with multiple projections. The nuts that are included in a welding process are not the same as the typical ones. Rather, they are made with a specific design to be welded onto other objects.
 

Welding Basics & Working Principle

Welding is a process in which two or more objects are fused together by means of heat and pressure. When it comes to welding, it is most of the time a metal fusing process that comes to people's minds. However, welding can also be performed on thermoplastic materials other than metal. Welding is typically done between two selected spots on two objects respectively. When the metal is heated, it melts and can be fabricated with another piece of metal. The welded joint is called a weld or a weldment.

In some cases, welding is a process to heat one spot of an object and force the melted spot against the target object. When the weld cools down, the joint between the two objects is formed. In other cases, a third material is needed to form the welded joint. In this case, the parts to be welded are called the parent material, and the third material that is used to form the joint is called the filler or consumable. Typically speaking, the material of the filler is supposed to be similar in composition to the parent material.

Depending on the way the parts are fused, the materials to be welded, and how the consumables are used in the process, there are many types of welding. Each of the welding approaches applies particular techniques to create the joint between objects. With different methods, the strength and the property of the joints can be categorically different. One of the most common types of welding is resistance welding.
 

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Resistance Welding

Resistance welding is one of the welding approaches that do not include the use of any filler or consumable. Just like other types of welding, heat, pressure, and time are required in resistance welding. Yet, in resistance welding, the electric current is applied to generate the heat that is needed. During the process, a controlled amount of current passes through the welding spot of the metal. When the current passes through, the resistance of the material causes a short circuit and hence the heat is generated. It is called resistance welding as a result.

The primary advantage of resistance welding is that, since there is no filler included in the process, it is very cost-effective. Because this type of welding is easy to carry out and can be performed on almost every kind of metal material as long as it has electrical conductivity, there are various forms of resistance welding. Spot welding, seam welding, flash welding, and projection welding are frequently applied these days in several industrial settings.
 

Projection Welding

Projection welding is a type of resistance welding that is ideal for creating discreet individual point contacts to concentrate the current during the process. In most cases, the application of projection welding involves more than one small projection that is formed on one surface of the parts to be welded. The small projections on the welding surface have several configurations such as round dimples, ridges, circular corners, or extended corners of weld nuts. When two parent materials are put together, the projections concentrate the current flow and generate heat in these specific sites.

The force, power, and time that are involved in performing projection welding are important. The force should be just enough to create a tiny indent at the tip of the projection before the weld is created. The power and the time are crucial to the strength of the welds. The less the power is, the shorter the time is, the weaker the welds will be. However, with excessive power and time, the ambient areas around the projection will be melted. As a result, the force, power, and time should be carefully controlled based on the materials to be welded. To assure the welding quality, a projection welding machine is recommended for the job.
 

Nut Welding

Nut welding is essentially the welding used to attach threaded nuts to another piece of metal object. A nut welding is usually carried out by means of projection welding because the nuts may have a partial or full ring projection or multiple corner edges are formed during the process. Therefore, nut welding is also known as projection nut welding. Projection nut welding is very common in the automotive and appliance industry since nut welding is performed to create assembly points for screws and bolts.

As aforementioned, the nuts that are manufactured for projection nut welding comes in with special designs so that they can work best with the welding process. The material that is used to manufacture the weld nuts is usually low carbon steel or stainless steel. These steel-based materials have a rigid property and the welds are less likely to break with heavier loads. They are ideal for higher load applications.

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