Stud Welding News and Best Practices from Stud Welding & Fasteners

February 27, 2017 By mcampbell

When to Replace Welding Equipment

Stud welding has been around for a very long time. There are conflicting reports about who actually invented the process. A patent search reveals one possibility. In 1930, Boris S. Robinoff, along with Sumner E. Paine and Wrignol E. Quillen, published patent US1782316A and later sold the rights to Linde Air Products Company. At this point, the company used stud welding for submerged welding in the shipbuilding industry. It wasn’t long before it spread into other construction industries.

What also may have been around a long time is your stud welding equipment. It is common to grow fond of something you have owned a long time, but using old tools may not be a wise idea. Here are some questions to ask yourself that will help with the decision about when to replace welding equipment.

stud welding equipment repair

Is it obsolete? There is a difference between a classic car and a junk heap. Obsolete welding equipment is unlikely to become a classic, so it is a junk heap for sure! It may be hard to part with it, but once you use a newer model with its vast improvements, you won’t miss it.
Is it safe? Old equipment could cost you dearly because of an injury or because the lower-quality welds it produces could hurt your image and lose you some business.
Are you facing repairs? Repairs are costly in several ways. Not only will you be paying for them, but you will lose time on the job, which drops revenue. If your welding equipment is old, you may lose even more time, as it can be difficult to locate parts or find someone that knows how to work on them. When repair costs become greater than replacement costs, it is time to act.
Are you happy with results? If you find yourself constantly dealing with issues or the results are not satisfactory, replace the equipment. Not only is it frustrating to work with obsolete equipment, your welds won’t hold up as they should. Besides, if you are not happy with the results, why would your customer be? In addition, you could be liable should a weld fail.

Troubleshooting Your Stud Welding Equipment

Old equipment can be fraught with problems. Troubleshooting is necessary to decide if you should replace your equipment. Is the issue caused by the equipment, the consumables, the work piece, or user error? The process of troubleshooting will depend on the type and model of the welding equipment you have.

MIG Welding Troubleshooting

Any number of weld defects can result from problems with the equipment or the consumables. To make things more complicated, a defect can result from more than one issue. Here are a few issues:

Wire is not feeding. This is usually an equipment issue. One or more parts must be replaced, such as the trigger switch, feeder relay, control lead, liner, or adapter connection.
Erratic wire feeding. If the wire is feeding, but erratically, the liner probably needs replacing. There may also be debris buildup.
Short tip life. A number of factors can influence tip life, and it may well be the particular application that is to blame. It can also be user error, such as using the wrong size tip for the task. Other things to check are the drive roll tension setting, low-quality wire, or a defective drive roll.
Erratic arc. Consistent electrical conductivity is required for a proper arc, so look for what is hampering it. Possibilities include erratic wire feeding, worn or improper tip, gun neck is too straight, connections are loose, or liner is worn, damaged, or dirty.
Extreme spatter. Diagnosing this issue is complex and can be either equipment or non-equipment related. User errors include improper weld puddle protection, incorrect tip installation, incorrect shielding gas, and not keeping the nozzles and diffusers clean. Other possibilities include a contaminated work piece and electrical conductivity issues.
Running hot. The most common causes when the gun is getting too hot are loose connections, defective power cable, and exceeding the duty cycle. You can correct the latter only by using a higher-rated gun for the project.

A great source for troubleshooting your welding equipment is the dealer where you purchased it. They can also tell you the benefits of newer equipment and provide tips on maintaining your equipment so it lasts as long as possible. With preventive actions, including cleaning and developing a maintenance schedule, your new welding equipment will give you years of service.

For all your arc welding needs, including sales, service, and rentals, contact Stud Welding & Fasteners, Inc. We’ll help you with new equipment as well as accessories and parts. If you have a short-term need, ask about our rental welding equipment.

Atlanta Stud Welding Generator Rental

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.

September 28, 2016 By mcampbell

Industries That Use Stud Welding And The Benefits

Stud welding is a metal fastening technique similar to flash welding. In stud welding, we weld a specially shaped nut or fastener onto another part, typically a substrate or base metal. These fasteners take a variety of forms, but fall under general categories of threaded, unthreaded or tapped. We also call this “drawn arc welding” because it joins the stud and other metal piece by heating two parts of an arc. Many industries use stud welding because it offers a wide range of benefits.

Industries that Use Stud Welding

There are many different applications for stud welding, so it is no surprise that the process is used in many industries. Here is just a sampling of the different applications for stud welding:

Electrical. Stud welding is for mounting electrical components in cabinets and on panels, as well as for bonding panels and doors, and fixing wiring looms.
Heating and ventilation. Stud welding is useful for attaching hatches, covers, and flanges, as well as for mounting fluid chambers and fixing pipes and insulating material.
Mechanical. Stud welding is often used to fix fluid and air lines, mount handles or other mechanical components, or to attach machinery guards.
Food service. Large containers (think of the salad bar in restaurants and grocery stores, restaurant cooking surfaces such as griddles, and industrial size coffee makers) use stud welding.

Many other industries also use stud welding, including the automotive, construction, cabinetmaking, fabricating, environmental engineering, electrical, insulation, machine construction, railroad, and shipbuilding industries.

Types of Stud Welding

There are two main processes that fall under the category of stud welding: capacitor discharge stud welding and arc stud welding. Both processes offer benefits, but it’s important to understand the differences so you can make an informed choice about which process to use.

Shops that work with sheet metal commonly use capacitor discharge stud welding. It’s a semi-automatic process done with arc welding. However, its advantage is that you can weld studs of very small diameters to very thin material. Since making the weld cycle is incredibly fast, you can connect the studs to thin sheets of metal without showing distortion or discoloration. Another advantage is that you can more easily weld dissimilar metals.
Arc stud welding is a process the fabricating and structural steel shops commonly use. Arc stud welding’s main benefit is that it allows almost any size or type of stud to be welded. For this process, studs must be of a weldable material and designed using a special arc stud tip. The arc process offers a full-fusion weld that magnifies the strength of the stud itself. One can apply arc stud welding to different material types, including mild steel, stainless steel, and aluminum.

Benefits of Stud Welding

Here is a deeper look at the many benefits offered to businesses and manufacturers through the use of stud welding:

Convenience. The welder needs access to only one side of whatever is being worked on, which means the work can be done in areas where it would not be possible, or when it would be highly inconvenient or costly to perform other types of welding.
Speed. This is one of the biggest benefits of stud welding over other processes. This type of weld takes milliseconds, so it vastly increases productivity. In contrast, traditional welding can take several minutes to accomplish the same task. The fast attachment this process offers could be the #1 reason it is used in so many industries.
Strength. Stud welding is incredibly strong, with strength of the weld being greater than either the base metal or the stud. Welds made using this process have a longer life than the products they make, ensuring there will not be any faulty joints where the welds are made.
Cost Efficiency. Stud welding does not have the maintenance costs that come with other types of welding. Additionally, since stud welding saves time, it also decreases associated costs.
Safety. Other welding types have a tendency to splatter hot metal, which can present a serious danger to skin and eyes. Stud welding has no weld splatter due to a ceramic shield that covers the work area, so it is much safer to perform than other types of welding.
Improved design. Stud welding provides an “invisible” fix for surfaces where final appearance, security, or hygiene is important – another advantage it offers over traditional welding methods.

Manufacturers are increasingly using stud welding. At Stud Welding and Fasteners, we pride ourselves on providing friendly and competent service for all your stud welding needs.