Meta Description: Discover how cold heading revolutionizes fastener production! Learn about material savings, precision, and why 80% of high-strength bolts use this method.
Cold heading shapes 90% of modern fasteners—from micro M2 screws to massive M36 bolts—without heat or waste. This guide explores how this efficient process delivers 10,000+ parts/hour with aerospace-level precision, making it the backbone of automotive, construction, and aerospace industries.
What is Cold Heading?
Cold heading is a room-temperature metal forming process where wire is cut and shaped into precise fastener blanks using 500–2,500 ton presses. Key stages:
- Wire Feeding: Spooled steel (Φ1mm–Φ30mm) fed into machine
- Cutting: Shear to exact length (±0.1mm tolerance)
- Forming: Multi-die stamping creates heads/threads
- Thread Rolling: 80% faster than machining
Key Advantage: Zero material waste vs. 40% in CNC machining.
5 Industries Transformed by Cold Heading
| Industry |
Typical Fasteners |
Material Used |
| Automotive |
Engine bolts, wheel studs |
10.9 Grade Steel |
| Aerospace |
Titanium rivets, shear bolts |
Ti-6Al-4V, A286 |
| Construction |
Anchor bolts, Hilti nails |
ASTM A325, 316 SS |
| Electronics |
M1.6 phone screws |
Brass C36000 |
| Medical |
Bone screws, implant parts |
316LVM Stainless |
Case Study: Toyota saved $2.5M/year switching to cold-headed wheel bolts.
Cold Heading vs. Machining: Key Differences
| Parameter |
Cold Heading |
CNC Machining |
| Speed |
400–1,200 ppm |
5–50 ppm |
| Material Use |
98–100% efficiency |
60–70% efficiency |
| Strength |
Grain flow maintained |
Cut grain structure |
| Cost (M10 Bolt) |
$0.12–$0.35 |
$1.50–$4.00 |
Material Compatibility Chart
| Material |
Cold Heading Suitability |
Max Tensile (MPa) |
| Low-C Steel |
Excellent (CQ <0.25%) |
500–700 |
| Alloy Steel |
Good (40CrMo) |
900–1,200 |
| Stainless |
Moderate (304/316) |
600–900 |
| Aluminum |
Limited (2000/7000 series) |
300–500 |
Pro Tip: Use lead-free steel (SAE 1008B) for eco-friendly production.
5 Technical Advantages of Cold Heading
-
Thread Rolling Superiority:
- 300% fatigue life vs. cut threads (SAE J2638)
- Surface roughness Ra 0.8μm (ISO 1302)
-
Precision Tolerances:
- Diameter: ±0.025mm
- Head height: ±0.05mm
-
Speed to Market:
- Tooling setup in 2hrs vs. 2 weeks for forging
-
Energy Efficiency:
- 0.3 kWh/kg vs. 1.2 kWh/kg for hot forging
-
Sustainability:
- Zero cutting oil waste
- 100% recyclable scrap
Cold Heading Process Flow
- Wire Inspection: UT testing for defects
- Phosphate Coating: Zinc phosphate layer for lubrication
- 1st Blow: Upset preform shape
- 2nd Blow: Final head form
- Trimming: Flash removal (≤0.1mm)
- Heat Treatment: Case hardening (HRC 32–39)
FAQs: Solving Production Challenges
Q: How to prevent cracking in high-carbon steel?
A: Use 850°C spheroidize annealing pre-treatment.
Q: Best lubricant for titanium cold heading?
A: Molybdenum disulfide (MoS₂) with paraffin carrier.
Q: Minimum order quantity for custom dies?
A: FINEX offers 5,000pcs MOQ with 15-day lead time.
Why Choose FINEX Cold Heading Services?
- 50+ Press Capacity: 3T to 2,500T for M1–M64 fasteners
- Smart Tooling: AI-driven die wear prediction
- Certifications: IATF 16949, AS9100, ISO 14001
- Custom Solutions:
- Micro forming for medical screws
- Six-sigma defect rate (<0.65 DPMO)
Free Resource: Download Our Cold Heading Design Guide
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