Arc welding method and apparatus

A welding apparatus for welding a substantially metal component to a metal workpiece, said component comprising a metal weld region and a connector region, said apparatus comprising:

• a weld head operably holding said weld region of said component adjacent said workpiece and inducing a weld arc between said weld region and workpiece to create a weld pool of molten material, whereby the weld head subsequently displaces said weld region into said weld pool;
• a pressurized fluid source;
• a fluid seal positionable adjacent only the connector region of said component;
• and
• a fluid flow controller operably directing a fluid of the pressurized fluid source between said weld head and said connector region within the fluid seal and the weld pool so as to deflect any airborne fluid residue of the weld pool away from said connector region of said component.

A method of welding a substantially metal component being a weld nut having a metal weld region and a connector region to a metal workpiece, comprising the steps of:

• engaging the nut with a welding machine;
• creating a weld arc between the metal weld region of the nut and metal workpiece to create a weld pool of molten material;
• initiating a pressurized fluid flow between the welding machine and the nut so as to be disposed between the connector region of the nut and the weld pool to deflect any airborne fluid residue of the weld pool away from the connector region of the nut during the displacement of the nut into the weld pool;
• directing the pressurized fluid flow through a central aperture of the nut;
• and;
• placing an insert in frictional engagement with internal threads of the nut to form a sealed channel with the threads through which the fluid flow is directed.

A welding system, comprising:

• a substantially metal weld nut having a metal weld region and a threaded connector region formed about a central aperture, the weld adapted for weld attachment to a metal workpiece;
• a weld head having a sleeve operable to hold the weld region adjacent to the workpiece and induce a weld arc between the weld region and the workpiece to create a weld pool of molten material, wherein the weld head subsequently displaces the weld region into the weld pool;
• a pressurized fluid source;
• a fluid flow controller operable to direct a fluid from the pressurized fluid source between the weld head and the weld nut and the weld pool so as to deflect any airborne fluid residue of the weld pool away from the connector region of the weld nut;
• a plurality of threads of the threaded connector region;
• and
• a directing member including a cylindrical body engageable with the plurality of threads of the threaded connector region to form a substantially sealed thread channel and operable to direct the fluid through the thread channel.

A welding apparatus, comprising:

• a substantially metal weld nut having a metal weld region, a threaded connector region formed about a central aperture and an upper surface, the weld nut adapted for weld attachment to a metal workpiece;
• a weld head having a sleeve operable to hold the weld region adjacent to the workpiece and induce a weld arc between the weld region and the workpiece to create a weld pool of molten material, wherein the weld head subsequently displaces the weld region into the weld pool;
• a pressurized fluid source operable to supply a fluid;
• a fluid flow controller operable to direct the fluid between the weld head and the weld nut and the weld pool so as to deflect any airborne fluid residue of the weld pool away from the threaded connector region adjacent a central aperture of the weld nut, the fluid flow controller including:
• a substantially hollow fluid transmitting member having an end stop for substantially sealed engagement with the upper surface of the weld nut, the transmitting member operable to direct the fluid through the central aperture of the weld nut;
• a cylindrical directing member engageable with the threaded connector region to form a substantially sealed thread channel and operable to direct the fluid through the thread channel;
• a control valve disposable between the fluid source and the weld nut for inducing a spiral flow path of the fluid;
• and
• a deflector member disposed in the flow path of the fluid in front of the control valve and angularly inclined in a direction of the flow path, the deflector member assisting to gradually deflect the fluid toward the thread channel.

An arc welding apparatus, comprising:

• a plurality of threaded weld connectors each having a plurality of threads;
• a welding machine having a weld head capable of externally grasping the threaded weld connector;
• a sealing element longitudinally displaceable in the weld head, the sealing element operable to contact the plurality of threads of the threaded weld connector such that a sealed channel is formed between the threads and the sealing element;
• and
• a pressurized fluid source connectable to the welding machine operable to supply a fluid flow within the sealed channel;
• wherein during an operation when a weld arc is generated by the weld machine between the threaded weld connector and a metal workpiece to create a weld pool of molten material, and the weld connector is subsequently displaced into the weld pool, an airborne fluid residue of the weld pool is deflectable away from the threads of the threaded weld connector by the fluid flow.