Month: June 2020

When performed correctly, stud welding applications can provide a fastening system with connection points stronger than either the welding stud or the base material. The basic result of a stud weld is a chemical combination of the two metals being connected, rather than just an adhesion. This chemical bond between two different components is a critical tool for a wide range of manufacturing industries. If you rely on the stud welding process for your production operations, you can find everything you need at Northland Fastening Systems to get your job done efficiently and effectively. From studs in a comprehensive range of dimensions to welding tools for rent and purchase, our expert technicians and knowledgeable staff can help you get all the accessories you need.

Whether you are using drawn arc or CD (capacitor discharge) techniques, each stud welding process has similar stages and requires the same level of inspection processes. Weld inspection is a critical aspect of a well-executed welding operation. For all stud welding processes, the following basic components comprise a thorough weld inspection.

1. Spattering: One sign of an obvious issue in a weld is spattering, which is splashed or spattered molten metal around the weld point, that points to a too-hot weld. Overly hot welds cause weaker connections and shorten the stud length more than desirable.

2. Burn through: Another sign of a too-hot weld is burn through of the stud too deeply into the base material. This issue leads to rapid metal fatigue and a poor visual result.

3. Dull/low flashing: A cold weld, on the other hand, shows slightly different, but easily identified issues. First, a cold weld problem results in dull flashing or a low level of molten metal around the weld point. Cold welds can also result in a failed connection or damaged stud.

4. Stringing: Another clear sign of a cold weld problem is metal stringing around the weld point. This slight spattering has longer, duller strands of molten metal around the connection than hot weld spattering.

5. Undercut: If poorly centered, improperly aligned, or welded with too much lift, a weld can show an undercut at the connection point. This means the weld was “hung up” and has a weak connection. Other issues of an undercut is little flashing and a long stud length.

6. Bend: The bend test is one last test after initial inspections that can reveal welding problems. In stressing a stud and connection point by bending it back and forth, you can ensure your welding tools are correctly calibrated. If the weld connection point breaks before the stud, your tools are not performing correctly. In any good stud weld, the stud should snap before the connection point cracks or breaks.

With these simple visual inspections and the bend test, you can eliminate the majority of weld issues. To learn more about the stud welding process and troubleshooting a weld, contact Northland Fastening Systems at (651) 730-7770. You can also request a quote online to get started with us today.

Stud welding is typically associated with the fastening together of two steel bodies. While this is often the case, welding can also be used with a variety of metals and other nonmetal materials such as plastics. One of the secondary metals used in welding processes is aluminum. In fact, when it comes to welding studs on an aluminum surface material, the right process can create a strong weld that is effective in the long term. If you are working with aluminum in your stud welding process, Northland Fastening Systems (NFS) provides the tools, studs, and expertise you need to get the job done effectively and efficiently.

Welding studs on an aluminum surface can be a more difficult task than working with steel materials, largely because aluminum is a much more conductive metal, both thermally and electrically. A higher conductivity at the weld point draws heat away from the stud, rendering the temperature insufficient to form a strong connection. Without correctly preparing the weld process, welding to aluminum surfaces can be like trying to heat up a cup of coffee during a blizzard.

The best way to achieve a strong stud connection to aluminum is to prepare the surface and correctly calibrate the stud welding process.

• Surface Preparation: Aluminum surfaces can easily build up oxides. For a quality weld, these oxides need to be removed with a stainless steel brush. After brushing off oxides, surfaces should be wiped down with a non-VOC cleaner.
• Weld Speed: Both CD and drawn arc stud welding processes should be done as quickly as possible when working with aluminum. Speed can help limit the unwanted conduction of heat away from the weld. CD weld times, for example, are completed in 10 milliseconds.
• Shielding Gas: If you are using drawn arc stud welding with aluminum, then shielding gas is a requirement. This gas is critical in generating enough heat at the weld point and combating aluminum’s higher conductivity. Most welders use 100% argon shielding gas, but 100% helium or a mixture of helium and argon are also useful in aluminum welding.
• Ceramic Ferrule: Like shielding gas, ceramic ferrules are necessary when drawn arc welding onto an aluminum surface. This ceramic ferrule contains the tip of the welding stud, and more effectively distributes heat and shielding gas around the weld point.
• Stud Design: Another key difference in aluminum welding is the stud design for drawn arc stud welding processes. The best aluminum studs have a built in ignition tip that burns away before the weld is performed. This allows the welding arc to last longer and generate more heat than a typical welding stud would.

To troubleshoot an aluminum stud weld result, examine the connection point and surrounding surface material. If there is a flash ring or if the stud and/or surface are left shiny, the weld was not performed correctly.

Learn More About the Stud Welding Process

To learn more about the stud welding process when working with aluminum, contact Northland Fastening Systems at (651) 730-7770. Request a quote online to get started with us today.