Stud Welding Archives - Stud Welding & Fasteners, Inc.

April 23, 2018 By mcampbell

What Type of Materials Can Be Stud Welded?

Stud welding is a time-saving and less-expensive method for many welding projects. In addition, the strength created during the process can make it a preferred method for many types of work. Typically, this type of weld will outlive the rest of the product, solidifying its placement at the top of the welding options. By ensuring a durable and long-lasting finished product, you are doing yourself a favor.

Different types of materials can be stud welded, including steel, aluminum, brass, and copper. The variety of materials that can effectively be welded, as well as the multiple uses, make it a very versatile technique. Educating yourself about the different materials can go a long way toward ensuring you are choosing the right material and the best stud welding tools for your stud welding project.

Steel

Low, medium, high-carbon, and stainless steel can always be stud welded. Low carbon stud welding does not require pre or postheating. Medium and high carbon, above 0.25, will require preheating to prevent cracking. Postheating is also recommended for higher carbon levels. Steel is a great stud and base material. As a side note, stud welding steel alloy is limited and generally not recommended. Try to avoid this unless your options are severely limited.

Aluminum

Another preferred stud welding material is aluminum, both as a base material and a stud. Aluminum and aluminum alloys are both good options, with aluminum alloy being a good option for a stud. Although aluminum alloy material is the better option for a stud, pure aluminum will work well.

Brass

Brass is a good stud welding material, if it is lead-free. Using brass as a base can be an effective alternative to other materials. Strong options for studs include brass, mild steel, and stainless steel. The capacitator discharge process is the best option when stud welding brass.

Copper

Copper is another material with distinct advantages and disadvantages. If you are looking for a project without marking, the copper base should be used with brass weld studs. Stainless steel and mild steel are good options as well, but they may result in marking. If you are concerned with marking, copper seems to be the logical choice. High-speed capacitator discharges are the best option for stud welding copper.

Stud Welding Selection Chart

Below you will find a chart that will help determine stud welding material selections. Prepared by AWS Committee on Arc Welding and Cutting, Production Fastening Systems, LLC, published the chart.

Stud Metal Options

Arc Stud Welding vs. Capacitor Discharge

Arc stud welding is a reliable fastening method that will weld almost any size stud to a metal piece in a very short time. This method creates welds on base metals that can be as thin as .048 inch. The process requires a power supply, stud welding gun, and metal fasteners.

A capacitor discharge (CD) can be completed even faster than an arc stud weld. The quick method of welding will reduce marking and burning on the materials. The CD method is typically used when the result will need to be free of markings and have a smooth appearance. The fasteners used in capacitor discharge are relatively unchanged following the process, so this can be an effective tool if you are looking to cause minimal changes to your fasteners and studs.

Product result, tools available, and type of weld will all determine which materials should be used for stud welding. It is imperative to do your due diligence when you are preparing a stud welding project. The materials you use, the methods you employ, and your overall experience in welding will all play a factor in the success of your welding project. If you are unsure of results or combinations, a quick online search will lead to thorough explanations and video tutorials. If you need help purchasing stud welding equipment, do not hesitate to give us a call at the Stud Welding Store!

March 28, 2017 By mcampbell

Tru-Weld: Then and Now

Tru-Weld Stud Welding is one of the most reputable sources for stud welds in the world. In basic terms, stud welding is the fusion or a metal shaft (or “stud”) to a work piece using a high-power electrical detonation. This yields a stronger bond than traditional forging or welding. Companies have relied on Tru-Weld’s products for decades, but how did this manufacturer become such an industry mainstay? Learn the history of Tru-Weld to see how one company transformed stud welding forever.

1929: Foundation of TFP Corporation

About 30 years before the Tru-Weld name earned a reputation for quality weld studs, it was TFP Corporation, a cold-form manufacturer in Lakewood, Ohio. Cold forming is the process of forging metals at high speed and high pressure, at near room temperatures. TFP Corporation produced cold-form goods and services for 30 years, growing as a company and soon expanding into another, related sector – stud welding.

Mid to Late 1950s: Stud Welding Gains Popularity

In the mid to late 1950s, stud welding had become popular due to emerging technologies and new advancements in engineering and manufacturing. Industries such as construction, automotive, aerospace, marine, and military defense began to demand higher-strength studs and fasteners than manufacturers had previously produced. Stud welding came about as a solution to this problem.

Stud welding fuses a threaded or nonthreaded metal stud or shaft with another metal part, such as a base metal. Stud welding uses a high-speed welding process. First, a hand tool called a stud gun places a welding stud in contact with the base or substrate metal. Then, a weld arc melts the welding stud base and an area for metal fastening. The welding stud is forced into the melted area and held in place until the metal solidifies. This high-quality fusion takes place in just milliseconds using two methods: drawn arc and capacitor discharge (CD) welding.

Drawn arc welding is best for large diameter fasteners and rougher base metals. Stainless steel, aluminum, and mild steel are appropriate base options for this type of welding. CD welding is more appropriate for smaller diameter fasteners and thin base metals. Due to the incredibly fast nature of the weld, it doesn’t distort, burn, or discolor the metals. Manufactures can make almost any shape arc and CD stud, as long as one end of the fastener is designed for arc welding or CD welding.

1959: Tru-Weld Joins the Market

In 1959, TFP Corporation joined the trend toward stud welding. It created the Tru-Weld Division to cater to the growing consumer demand for strong, high-quality, application-specific weld studs. The superb quality and craftsmanship of Tru-Weld’s products quickly led to the division’s success, and it soon became an industry leader of weld stud manufacturing and sales. Tru-Weld produced custom studs for specific industries and customers, all using special manufacturing techniques to ensure their high strength and durability.

1970: Tru-Weld Moves to Medina, Ohio

During the 1960s, Tru-Weld continued to lead the market for stud welds and weld fasteners for everyday tools, yard machinery, automobiles, bridges, aircrafts, ocean liners, steel buildings, military vehicles, and more. Under the capable direction of President Harry Workman, TFP Corporation grew to a total of 25 employees, and slowly began the transition to a new location in Medina, Ohio.

The company chose Medina for its spacious 155,000-square-foot manufacturing plant, which was perfect for TFP Corporation’s rapid expansion. The corporation made the move in multiple stages to minimize the disruption to workflow. Most of the move used rail cars to transport heavy equipment and machinery due to weight restrictions on the roadways. Once the move was completed, TFP Corp. and Tru-Weld really began to thrive, picking up distributors around the nation. The large facility enables the company to keep many common lengths and diameters in stock for faster delivery times.

Tru-Weld Today

Today, Tru-Weld remains one of the most popular weld stud manufacturers in the world. Still operating from its facility on Lake Road in Medina, Ohio, Tru-Weld has stayed true to its original mission and vision – to bring the highest-quality welded products to people around the globe. They are a go-to source for arc stud and CD stud welding, weld studs, and a variety of related equipment. Whether you need welding guns and generators or dependable stud weld accessories, Tru-Weld has what you’re seeking.

Tru-Weld understands the guidelines and best practices for stud welding, such as setting appropriate amperage and time for weld base diameters, aligning accessories correctly, and ensuring a clean and solid ground connection. They’ve been in the business of producing stud well products and accessories since 1959, far longer than most competitors. They continue to invest in emerging technologies to keep their manufacturing practices as safe, efficient, and modernized as possible for the benefit of their customers. To purchase Tru-Weld products from a licensed distributor, come to Stud Welding & Fasteners, Inc.

February 8, 2017 By mcampbell

How Stud Welding is Used to Secure Bridges

People have crossed waterways and other difficult spans in different ways through the centuries. Durability wasn’t as important back in horse and buggy times, but today’s bridges must be strong. Thankfully, something else changed besides the type of traffic – the 1880s saw the introduction of steel.

Steel did have limitations in the beginning, however. It wasn’t until the 1930s and the development of stud welding that people could use steel to accomplish new feats. Stud welding makes bridges sturdier and permits modern designs. If you want to earn a bridge welder salary you must learn how stud welding works.

What is Stud Welding?

Stud welding, or more accurately, drawn arc stud welding, is a process unlike spot and resistance welding. Rather than using electric current and high pressure, stud welding uses an electric arc. There are two stud welding processes that can be used – capacitor discharge (CD) and arc stud welding.

Capacitor discharge. This process is semi-automatic and ideal for working with small diameter, shorter studs, and thin materials. Typically, people use this type of welding for sheet metal, not for bridges.
Arc stud welding. Ideal for use with a variety of materials of nearly any size, people use arc stud welding for bridges and other structures.

What are the Benefits?

The beauty of this process is that various materials can be used and the fastener is attached without marring the other side of the workpiece. This makes it aesthetically superior. Stud welding is also more secure and won’t work loose, which is essential for bridges, because of the constant vibration of traffic. Another benefit of stud welding is that it is easy to learn. Even a novice welder should pick up the skill readily.

How to Join a Bridge Crew

Qualification approval for proficiency is necessary before acceptance on a bridge project. This usually involves completing 10 studs in the diameter and position that will be needed. The welder would also be using the same equipment and materials. These are tested for failure by torque testing, bend tests, and other methods.

The visual result is also important. Cold weld, hot weld, or stud hang-up results will disqualify the welder. The visual inspection is looking for even flash, a shiny hue, proper flash height and after-weld length, as well as other guidelines for the project.

How Stud Welding is Used on Bridges

There are many places on bridges that stud welding is used. One important area is connecting the bridge at the ends. You may have noticed that when you drive onto a bridge, you hear a gentle “thump, thump” noise. A metal plate that extends between the bridge and the road causes this. This metal expansion joint allows the bridge to contract and expand with temperature changes. On the back of that plate, stud welding holds it in place by anchoring it to the concrete sets.

Stud welding also creates adhesion between other plates and steel to concrete and reinforced mesh. This is part of the steel girder to slab construction process. Sometimes shear connectors welded to the top flanges of the girders are done off-site and shipped to the project. Other shear connectors must be done onsite.

Outlook for Bridge Construction

In 2016, the American Road & Transportation Builders Association (ARTBA) reported that there are 58,495 structurally deficient bridges in the United States. Other reports put that number much higher and note that more than 20,000 of them are “fracture critical.” More than 12% of bridges in some states are in trouble.

The Federal Highway Administration (FHWA) recognizes that nearly twice the current budget is needed to deal with this backlog, with state, federal, and local governments working diligently to increase their bridge investments.

A number of bridges will be replaced as a result. For example, the new Tappan Zee Bridge will span the Hudson River in New York to replace the Governor Malcom Wilson Tappan Zee Bridge, and should be completed in 2018.

In addition, many interstate bridges are being expanded to accommodate more lanes, improving America’s infrastructure. With all this in mind, the bridge welder market should grow 15% from 2010 to 2020.

Other Applications for Stud Welding

As the industry changes, stud welders will continue to be in demand. Currently, stud welders are needed in more than 200 industries. Growth in many of these, including alternative energy markets, assures job growth for stud welders.

Getting stud welding training and obtaining welding certification, such as through the Ironworkers/AWS National Welding Certification Program, will open doors. Some projects hire certified welders only, so your options will be limited to some degree without certification.

For all your stud welding equipment and service needs, turn to Stud Welding & Fasteners, Inc. where “Our word is as strong as our weld.”

December 30, 2016 By mcampbell

What is Friction Stud Welding?

Friction stud welding might not mean much to people who aren’t in industrial businesses, but the technology is something everyone should be able to appreciate. This modern marvel uses pressure to bond materials in a truly unique way.

The Science of Friction Stud Welding

Friction stud welding is a method unlike any other. Instead of using external heat from electricity, the bond between the materials is formed entirely by friction. The stud is forced against the parent material carefully. More pressure is applied as the stud is rotated at a high speed. The rubbing of the two surfaces causes extreme heat due to friction (hence the name).

The heat is so great that the metals melt and flow. The rotation forces out any surface impurities or other unwanted materials, making the weld clean. The molten metals bond with each other. Rotation is stopped and the weld is completed.

Friction Stud Welding Applications

Friction stud welding is much more costly than arc stud welding. Not only is it more difficult, but it’s also more time consuming. Arc stud welding happens in a matter of milliseconds, but friction stud welding can take several seconds or even minutes to complete.

Although it is trickier, friction stud welding is better suited to certain applications than other types of welding. Arc welding can present problems in certain cases, especially due to the heat and potential for open flames. The presence of electricity can be an issue, as well. As a result, friction stud welding is used in many different cases, including:

Underwater welding. Electricity cannot be used underwater, yet many items cannot be removed from the ocean for repairs (such as the supports of a permanent oil rig). Friction stud welding is perfect for this application, since it works equally well underwater without additional dangers. Subsea pipelines are another particular example. They can be kept live during the process.
Volatile environments. There are many areas where an open flame or a current of electricity would be dangerous. Any place with explosive gas or certain zoning restrictions is another great candidate for friction stud welding. The bond is made without any open flame or spark, making it much safer in these areas.
Materials which are difficult to join. Some metals are hard to bond in traditional fusion welding methods. Friction welding creates incredible pressure, making it easier to create a full joint between these kinds of metals.

Significance of Friction Stud Welding

Each type of welding offers its own advantages and disadvantages. Friction stud welding is useful because it forms bonds at relatively low temperatures, making it safe for sensitive applications and conditions. It also avoids many arc welding problems, like weld contamination. There is no electric current or liquid phase, meaning there is no additional hydrogen, nitrogen, or oxygen. This means cleaner and highly dependable welds.

Friction stud welding also offers a finer weld structure. This is because the cooling time is rapid and the application itself fosters a tighter connection. Friction welding might not be the most cost effective method, but in some cases it is necessary. Friction stud welding without doubt is a fascinating style of welding.

December 28, 2016 By mcampbell

A Quick Look At The Process Of Stud Welding

Like everything else, each type of welding has its own benefits and disadvantages. Different styles are better suited to different applications. Stud welding is more popular than ever thanks to its incredible speed. This quick and efficient type of welding is often used in the manufacturing of cookware, automobiles, aerospace, and marine products, to name a few. Stud welding provides some unique benefits for companies in these industries.

Stud Welding Is Strong

Stud welding is incredibly strong. In fact, the weld itself is much more durable than the stud or the parent material. The joint will often outlast the product, itself. This makes stud welding perfect for mass manufacturing since dependable products can be created quickly.

Stud Welding Is Amazingly Fast

As we stated, stud welding is very, very fast. It only takes milliseconds for the connection to be made. Any time production speed is key, stud welding helps immensely. This is important for smaller businesses, especially, since workers can focus less time on welding and more on assembly, testing, and other portions of manufacturing.

Clean Welds

One of the best things about stud welding is it avoids messy splatter. Other types of welding, like MIG welding, can generate large amounts of excess metal. Aside from being unsightly, weld splatter can actually damage materials and ruin the finish on many products. Even if the item is salvageable it will require reworking, costing more materials and production time. Stud welding offers a clean joint every time. This means there are fewer product losses, even on more delicate items.

Stud Welding Is Versatile

For most welding, the items must be unpainted and sanded. Stud welding is different. Even if the surface is painted or pre-coated, the weld will hold. This saves even more time during preparation, but also makes the welds more versatile since they can be completed at various stages of production.

Cost-Efficiency Of Stud Welding

We’ve all heard the expression “time is money.” It’s never truer than during the manufacturing process. The faster an item can be completed, the lower the cost for the final product. Stud welding is incredibly fast, but as we mentioned, it also takes less preparation and requires minimal cleanup. This means each item will be easier to produce and bring in more profit. No matter what size the company is, more profit is always a good thing.

Stud welding also saves money because the materials are less expensive. Traditional welding rods or wire can cost big bucks, especially when buying them in bulk for production. Opting for stud welding lowers the bill since the material costs are more reasonable, and in some cases, easier to find.

Stud Welding Can Be Easier to Learn

Stud welding doesn’t require quite as much skill as other types. Of course, any time you’re working with molten metal you should have the proper background and take all necessary precautionary measures. However, workers can learn to stud weld more easily, since it requires less prep and cleanup.

Stud welding isn’t the answer for every connection, but it’s an incredible choice for countless applications. It is the product of advancing technology and a constant search for maximum efficiency and value.