Services & Capabilities Cold Forging / Forming of Rivets, Fasteners & Microprecision Parts Metal Part Forming Simulation Modeling CapabilitiesProject Showcase Fabricated Low Carbon Steel Delay Core for the Electronics Industry Engineering of a Kovar Weld Stud for the Glass Seal Industry Cold Heading of a Large Headed Rivet in Brass for the Telecommunications Industry Cold Heading of a Stainless Steel Adjusting Screw for the Water Sprinkler Industry Cold Heading of a Brass Split Terminal Pin for the Electronic Connector Industry Cold Heading of Automotive Power Seat Transmissions

Engineering of a Kovar Weld Stud for the Glass Seal Industry

Engineering of a Kovar Weld Stud for the Glass Seal Industry

C &L Rivet was commissioned by a customer in the glass seal industry to design and fabricate a cold-headed version of their screw machined weld stud. This re-design would mean improved surface finish and product performance, as well as material and production cost savings. Our experts collaborated with their engineers to produce the new design and tooling for this upgraded process. 

Process a 0.0240" diameter...+/- 0.0010" throughout. Completed dimensions were 0.0370" long and 0.0460" in diameter Kovar wire to the specified size, holding tight tolerances of ± 0.001" throughout. Completed dimensions were 0.0370" long and 0.0460" in diameter, with a 16 RMS finish. To provide a total manufacturing solution, the parts were cleaned and packaged for shipping. During production, optical and dimensional inspections were carried out to ensure accuracy; in addition this part was subjected to our internal quality control measures. Turnaround time for this project was 6 - 8 weeks, with an annual shipping schedule of 500,000 units. For more details about this Kovar weld stud project, or how we develop cold-headed processes for screw machined parts, please see the table below or contact us directly. 

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Highlights from the Engineering of a Kovar Weld Stud

Product Description These parts are used in the electrical contact applications
Capabilities Applied/Processes
Primary:
Co-Engineering/Tooling Design
Cold Heading
Secondary:
Cleaning
Packaging
Equipment Used to Manufacture Part 2 Die 3 Blow Cold Header
Overall Part Dimensions Ø 0.0240" diameter
+/- 0.0010" Length
Tightest Tolerances ± 0.001"
Material Used Kovar Wire
Thickness: 0.024" dia round wire
Material Finish 16 RMS
In process testing/inspection performed Dimensional Inspection, Optical Inspection
Statistical Process Control (SPC) All Critical Dimensions
Industry for Use Glass Seal Industry Electronic Contacts
Volume 500,000 / Year
Delivery/Turnaround Time 6 - 8 weeks
Delivery Location USA
Standards Met Customer Specifications, 2D CAD Drawing
Product Name Weld Stud
Why did you choose this project to show case? Originally Screw Machined Part. Tool designing with customer's engineering team to convert to a cold headed process.

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