CD Stud Welding Archives - Stud Welding & Fasteners, Inc.

May 15, 2017 By mcampbell

The ACE-P100 Pin Welder Has Arrived!

Stud Welding & Fasteners Inc. recently acquired the ACE-P100, an insulation pin welder that is a drastic improvement over all the products on the market. We are proud to report that we have already taken delivery of the first unit sold by Tru-Weld.

How Does It Work?

Capacitive discharge stud welding systems weld studs from 14-gauge through 10-gauge weld pins and cup head pins. The welder uses the most up-to-date technology for pin welding. This product has proven to weld pins up to 10 gauge and CD studs up to 10 times faster than other pin welding systems.

This product utilizes new operational and safety features, including less-than-one-second recharge time for pin welding. It offers a touchscreen interface that makes it easier to use. There are thermal and voltage protections that help keep you safe while welding. It also includes contact and trigger indicators to ensure optimal safety while you use the pin welder.

What Are Its Best Features?

Weighing in at just over 10 pounds, the ACE-P100 packs several upgrades and improved features into its compact design. Besides the faster recharge time and intuitive touchscreen, there is a set-point discharge that allows the unit to discharge directly to a new set point. This enables you to continue working without having to discharge completely.

The unit also features universal input voltage, which allows you to plug and play. You will never need to re-tap the machine to adjust it to 110v or 220v input voltages. Its low-input voltage capability allows you to continue with your work without having to use endless extension cords.

Safety indicators are in place to help ensure you and your welder are operating at optimum level. The machine has contact and trigger indicators that can help you troubleshoot your unit. Additionally, the unit uses thermal and voltage protection to prevent it from damage due to overheating.

How Is It Constructed?

The ACE-P100 unit is made of rugged materials; it comes in a lightweight, compact case that helps ease the struggle of carrying around a large welder. The unit is equipped with areas for increased airflow, which helps with efficiency. The rugged materials help ensure no components will become loose after handling and operation.

The new and improved hand tool was redesigned to reduce operator fatigue. This allows you to do more welding. The hand tool is equipped with an internal spring that adjusts to ensure the correct amount of pressure is applied whenever you are welding. The hand tool is also versatile, and can be configured for B collets, collet Inserts, Euro collets, and standard tapered chucks.

Why is this Pin Welder Right for You?

The setup and welding process of this pin welder is simple. The touchscreen allows you to command your welder to do whatever you would like, and it gives you the capability to get your job done quickly and efficiently. Contact Stud Welding & Fasteners Inc. at (800) 936-1948 to find out what the ACE-P100 pin welder can do for your business.

May 24, 2015 By mcampbell

What Is CD (Capacitor Discharge) Stud Welding?

Stud welding is a technique similar to flash welding where a fastener or specially formed nut is welded onto another metal part, typically a base metal or substrate. The fastener can take different forms, but typically fall under threaded, unthreaded or tapped. The bolts may be automatically fed into the spot welder. Weld nuts generally have a flange with small nubs that melt to form the weld. Weld studs are used in stud welding systems.

CD Stud Welding Capacitor Discharge stud welding eliminates drilling, tapping, punching, riveting, gluing, and screwing; and is especially beneficial when working with thin gauge materials due to the absence of reverse-side marring or discoloration. This process is suitable for studs ranging in size from #4-40 (M3) thru 3/8-16 (M10). During the CD process, the capacitors are charged to a setting pre determined on the front of the power supply. The CD gun is loaded with a weld stud and pushed into the base material under spring pressure. The tip touches the workpiece which closes the electrical circuit. Upon trigger from the CD gun the capacitors are emptied, the stud and workpiece surface from a molten material and solidfy together forming a solid weld. The welding time for CD studs is approx 3 milliseconds.

It started in the 1940’s when a welder had to attach threaded fasteners onto ships in a naval shipyard. He did this by holding a stud flush against the base metal and welding a fillet around the base of the stud. This was a very slow process so he came up with the idea of holding the stud in an electrode holder and touching the end of the stud to the spot where it was to be welded on the base metal and quickly lifting the stud from the base plate drawing an arc and after a short welding time he pushed the stud down into the molten puddle that had formed during the arcing. This resulted in the extinguishing of the arc which in turn resulted in a contiguous weld between the base plate and the stud. This man realized that in order to obtain consistent results he would have to design a way to lift the stud a constant amount in order to have a constant arc length and a constant weld time. He came up with the idea of holding the stud in a chuck and using a solenoid to lift the stud away from the base plate which would create an arc and having a timer that would de-energize the solenoid after a predetermined amount of time. With the use of these modifications it was possible to achieve welding consistency.

Over the years welding stud manufacturers have made improvements to the stud welding process. On of which was the use of a solid aluminum flux ball attached to the weld base of the stud instead of the granular flux that bad been originally used. This was such an improvement over the granular flux, most stud manufacturers changed to the use of a solid flux over time.

Several standard handgun models are available from stock to accommodate routine applications, while automated production systems are available on a custom-designed basis for high volume applications.

Stud Welding & Fasteners, Inc. supplies CD stud welding equipment for a range of markets all over the United States, including the automotive, construction, and industrial, as well as original equipment manufacturers and building contractors. SWF offers externally threaded fasteners, shear connectors, concrete anchors, punching resistor studs, inserts, ports, pipe and cable hangers, weld studs and bosses, and the equipment used to apply, assemble, and weld stud fasteners. Give us a call at (800) 936-1948 for more information.

February 13, 2015 By mcampbell

CD Stud Welding – How It Works and How It Doesn’t Work.

Stud Welding is a simple process, but it’s also simple to make it not work which can frustrate your operators.

Here we’ll discuss the process of CD Stud Welding and what to look for if you’re having trouble.

CD = Capacitor Discharge = Stored and Released Energy

Capacitor Discharge Stud Welding, Oklahoma It’s hard to fix something if you don’t know how it works, so let’s talk about the process of CD Stud Welding.

CD means Capacitor Discharge. Energy/Voltage is stored in the Capacitors and Discharged when the guns trigger is pulled. This all happens in a millisecond.

CD studs will have an ignition tip at the weld base. This provides the proper gap, much like a spark plug needs the correct gap to attain a sufficient arc. The ignition tip will be eliminated during the weld process, and the spring pressure will take over and force the stud into the weld. Be sure you are using a high quality CD stud to ensure a repeatable weld! (Like the CD Studs we sell!)

Set Up is King

Proper setup of your equipment will make or break you.

Like we said, it’s easy to make CD Stud Welding not work, but just as easy to get it right!

Ground Connection – A loose, indirect, or improper ground will inhibit the weld from being focused at the weld base. Remember, the weld is going to happen in a millisecond. If any of that energy is lost somewhere else, your weld will be weak. We highly recommend grounding directly to your work piece, and a double ground is essential for aluminum.

Stick out – Set your gun up so that 1/8″ of the stud is protruding past your footpiece or tripod legs. Basically, the more stick out, the more you are compressing the spring. Then set your spring pressure if equipped.

Spring Pressure – Most newer CD Guns allow the spring pressure to be adjusted. Tightening the spring pre-loads the spring which will force the stud into the weld pool harder and faster. Set the correct spring pressure according to the diameter of stud you are shooting. The larger the diameter, the more spring pressure you want. Aluminum will also require more spring pressure relative to the same diameter stud in steel. Aluminum cools faster, so you want to get the stud into the molten pool faster.

Setting your voltage – Check your stud welder’s manual for the correct settings, but for most CD Stud Welders you have one adjustment on your power supply. Adjust the voltage according to the diameter of stud you are shooting. Larger diameter = more voltage. Aluminum also requires a higher voltage setting than a similar diameter in steel.

Surface Preparation – Because the CD Welding Process happens so quickly, the surface you are welding to is very important. The surface area should be clean and free of abrasions.

Waterjets and other cutting machines can leave an oily residue. Clean the surface with Acetone if necessary.
If you have to remove paint from your weld surface, use a very high grit sandpaper. You shouldn’t be able to feel grooves or scratches with your finger.
Location Marking – using a center punch to mark your location for the stud is inadvisable. Remember, the ignition tip on the CD Stud sets the proper gap for the arc process. When you put the ignition tip in the punch mark, you are reducing the distance of the stud to the surface and therefore will compromise the integrity of the arc and weld. Instead, use a template. We can set you up with a template tube adapter for the front of your gun that will eliminate the need for a center punch.

Service – Knowing how to use your stud welding equipment will improve your shops efficiency and your end product. Just call (800-936-1948) if you are having trouble with your equipment or your application. We’re here to help! One of our experienced service techs will be glad to help you!