What powerheads are typically used in Hot Upset applications?
Our Hot Upset applications commonly use the 500, 750, or 840 powerheads, selected based on the specific force requirements to achieve effective material flow.
Can hydraulic and servo powerheads be used in Hot Upset applications?
Yes, both hydraulic and servo powerheads are compatible with the Hot Upset process, allowing flexibility in handling different materials and forming requirements.
What’s the key to success in the Hot Upset process?
Maintaining a consistent core temperature in the workpiece during force application is essential. This prevents premature cooling and ensures the desired finished form is achieved.
What types of applications are well-suited for the Hot Upset process?
The Hot Upset process is ideal for harder materials that may crack or be challenging to cold form, and for applications requiring maximum hole fill, if the design allows.
Is Hot Upset an assembly or welding process?
Hot Upset is an assembly process because it permanently joins parts together without welding, making it distinct from traditional welding processes.
What is the typical cycle time for a Hot Upset application?
The average cycle time ranges from 3-4 seconds, depending on factors like material hardness, pre-form dimensions, and material mass.
What is the sequence of the Hot Upset process?
Head advances to contact the workpiece (rivet or tenon).
Electrical current heats the workpiece to a “molten-like” state, allowing material flow.
Force is applied to form the final shape.
A “hold time” occurs, similar to dwell time in orbital processes.
Head retracts to the home position..
What advantages does the Hot Upset process offer?
Hot Upset provides maximum shank swelling for robust joints, is effective for forming harder materials without cracking, and creates highly durable connections.
What challenges are associated with the Hot Upset process?
Challenges include higher tooling costs due to wear, significant power consumption, potential cosmetic imperfections, and added part handling requirements.
What does “cascading” mean in Hot Upset applications?
Cascading allows one transformer to support multiple Hot Upset heads, with one head engaging per cycle, enabling multiple forms within a single machine cycle.
What types of power sources are used in the Hot Upset process?
We utilize both AC and DC power sources to support various Hot Upset applications, accommodating different process needs and equipment setups.
How would you describe the Hot Upset process?
Hot Upset combines elements of press and resistance welding processes, enabling the forming of harder materials without fusing parts together.
What are typical applications for the Hot Upset process?
Ideal applications include door, hood, and floor strikers, seat back strikers, ball studs, firearms components, truck frame cross members, chain link pins, and high-strength hand tools.
