Abstract: A process for projection welding a steel weld nut to an ultra high strength steel component using a direct current projection welding machine is provided. The process includes placing a steel weld nut at a predetermined location on the steel component such that the at least one projection of the weld nut is in direct contact therewith. The DC projection welding machine passes a current through the at least one projection that is in direct contact with the steel component a predetermined amount of weld time, which in turn creates a resistance weld joint between the weld nut and the steel component as is known to those skilled in the art. The predetermined amount of weld time is less than 1 Hz (16.67 sec) and the weld joint between the weld nut and the steel component has a twist off strength greater than 30.0 newton meters (Nm).

Abstract: A lower electrode dressing tool for a projection welding machine is disclosed. The present invention includes a rotary dresser that refurbishes a projection welding lower electrode. The dresser utilizes the lower electrode's locating pin that stabilizes the dresser as its rotating cutting elements reshape and resurface the lower electrode. This allows for smoother and more accurate performance of the dresser.

Abstract: A lower electrode dressing tool for projection welding machine is disclosed. The dresser includes a rotating cutting mechanism that includes multiple cutting elements. The rotating cutting mechanism has an opening and locating pin in the interior of the mechanism that seats and stabilizes a lower electrode of a projection welding machine against the dresser. While the dresser is in motion, the multiple cutting elements ride against and dress the flat upper surface of the lower electrode.