HY-PAK® is a patented projection welding process developed by Newcor for solving problems generally associated with the welding of light gage coated sheet metal.
Projection welding is a rather tolerant process, permitting parameter variations to occur without seriously affecting the integrity of the weld. However, for light materials, the process becomes much more critical. As projections collapse under the initial force of die impact, heat is dissipated into the tooling instead of the projection causing surface discoloration.
Coated materials present additional problems. Higher currents are often required. Surface coatings are burned away, and coating material can be deposited on electrodes.
Newcor has developed a welding process that generates a high magnitude of heat for a short duration. Teamed with our low inertia weld head that is capable of carrying a 40,000 to 60,000 amp weld pulse and the mechanical follow-up characteristics to set down the projection in less than five milliseconds.
HY-PAK® welding is an operator-friendly process. It uses standard weld schedule setups and does not require special training.
Advantages & 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.
• Single Sided Welding
What Types of Material can be Welded using the HY-PAK® Process?
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.
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.
Who’s Using it
HY-PAK® Welding Hems of Hoods, Doors and Tailgates.
Welding of Fuel Tanks and Sender Units.
Sealing Gas-filled Shocks. Welding of Fuel Tanks and Sender Units.
Sealing Gas-filled Shocks.
Fuel Tank Components. Fuel Tank Components.
Aircraft Engine Honeycomb Seals. Aircraft Engine Honeycomb Seals.
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 Doors and Deck Lids. HY-PAK® Welding Hems of Doors and Deck Lids.
HY-PAK® Welding Hems of Doors. HY-PAK® Welding Hems of Doors.
–HY-PAK Projection Welder
(989) 752-3103 ext. 4375
John P. Sivey
President / CEO
(989) 752-3103 ext. 4305