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Methods to prevent welding deviation when using medium-frequency spot welders for convex-welded bolts and screws
Jun 30,2026
In mass production processes such as automotive component manufacturing and hardware product processing, weld deviation in convex-welded bolts and screws using medium-frequency spot welding machines can lead to assembly difficulties, workpiece rejection, and even subsequent loosening or fracture during operation. Below are the hazards, causes, and preventive measures associated with weld deviation.
I. Core Manifestations and Hazards of Welding Deviation
1. Key manifestations: bolts and screws deviate from their preset axes or become tilted, failing to be perpendicular to the workpiece surface; melt pool distribution is uneven, with a high likelihood of unilateral non-welding or burn-through defects.
2. Core hazards: Mild welding deviation requires rework, increasing costs; moderate welding deviation leads to uneven stress distribution and susceptibility to bolt loosening; severe welding deviation results in workpiece rejection and may even cause safety incidents in high-end applications.
II. The Core Causes of Welding Deviation
1. Failure of positioning fixtures: Wear of positioning pins or insufficient rigidity of the fixtures prevents accurate fixation of bolts and screws, resulting in positional deviation.
2. Improper electrode control: Misalignment of electrodes, abnormal end surfaces, or pressure imbalance may cause bolt displacement.
3. Improper parameters and operation: Mismatched welding parameters, non-standard operating procedures, or inadequate cleaning of the workpiece or bolt surfaces resulting in gaps.
III. Key Measures to Prevent Welding Deviation
1. Optimize positioning fixtures: Standardize the selection and maintenance of positioning pins, enhance fixture rigidity, and ensure precise positioning and secure fixation of bolts and screws.
2. Standardize electrode management: Calibrate electrodes to neutral position, perform regular inspection and maintenance to prevent electrode displacement, and ensure uniform force distribution.
3. Optimize welding parameters: Set parameters based on workpiece characteristics and employ constant current control to prevent welding deviation caused by current fluctuations.
4. Standardized Operations and Pre-treatment: Thoroughly clean workpieces and bolt surfaces to prevent operational errors, and establish a routine maintenance protocol.
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Wuxi HAIFEI Intelligent Equipment Co., Ltd.
Wuxi HAIFEI Welding Equipment Co., Ltd.
Add: 28 Shuiyun Road, Yuecheng, Jiangyin, Jiangsu Province, China. (Postal Code: 214404)
Mobile: +86 18151507807
Email: info@jshaifei.com