Four General Properties Every Drawn Arc Stud Welding Technician Should Know

Drawn arc stud welding is one of the most important manufacturing operations in large-scale steel and composite construction. From its first key uses in shipbuilding to its common uses today in bridge construction, roadwork, automotive fabrication, and more, drawn arc stud welding has a large role to play in manufacturing industries. Because it is so important to a range of industries, stud welding technicians need to have a deep understanding of what makes a strong weld and why. If you are working with stud welding for any project, Northland Fastening Systems (NFS) has stud welding tools for rent or purchase, studs in a comprehensive range of dimensions, stud welding accessories, and the expertise of its own stud welding technicians—all to help you get the job done correctly and efficiently.

 

Drawn arc stud welding has a large range of specifications, calibrations, and additional factors to take into account. Without delving into the numbers and precision often needed to provide a strong weld connection, every technician should know the four basic properties involved:

 

  • Surface Preparation: Drawn arc stud welding can vaporize thin layers of contaminants like paint, rust, or oils, but before welding, surfaces should still be prepared correctly to ensure a strong connection. Any thick coatings must be removed as metal-to-metal contact during the weld is critical to generate an arc. If thicker coats cannot be removed, you’ll need a mechanical punch to create a metal-to-metal connection.
  • Ferrules: Drawn arc stud welding uses ceramic ferrules around the weld point. These ferrules contain molten metal during the weld to prevent splatter and shield the arc as it is generated. These ferrules also prevent air flow into the weld to control oxidation, and they protect nonmetal materials around the weld point from charring. Ferrules are chipped away from the weld point when the stud and surface material cools.
  • Shielding Gases: Inert or semi-inert shielding gases are typically made up of 100% argon or a mixture of argon and helium. These gases protect a drawn arc stud weld point from oxygen and water vapor during the weld. Shielding gases can also be generated with a flux that outputs a semi-inert gas like carbon dioxide when heated in the weld.
  • Flash: Every stud weld creates a flashing of molten metal around the connection point. This flashing can be a sign of a good or bad weld depending on its condition. In a drawn arc stud weld, flashing should be within the ferrule containment and show complete fusion around the entire stud. If you were to take a cross section of the weld, that fusion would be around the base of the stud beneath the surface as well.

 

Drawn arc stud welding is a complicated process that is used in a broad range of applications. To learn more about drawn arc stud welding, contact Northland Fastening Systems (NFS) at (651) 730-7770 or request a quote online.

Working through the Numbers for Your Stud Welding Equipment

The widespread use of stud welding in the manufacturing world, attributed to the broad variety of stud welding applications, can sometimes be misleading. While a diverse range of welding operations, materials, equipment, and dimensions are standard in stud welding practices, the calibration, sizing, and material requirements for each combination of factors create very complicated differences between any given stud welding operation. Sometimes the differences in weld specifications are extreme, which means that welding technicians need an exact understanding of what is and isn’t possible with their stud welding equipment. No matter what types of stud welding equipment, materials, and dimensions you work with, Northland Fastening Systems (NFS) can provide the tools and studs you need to get the job done.

Breaking down the numbers specific to the stud welding equipment, processes, sizing, and materials you’re working with can be a difficult task. To work through these numbers, we’ve listed basic specifications into the following charts.

 

Stud Diameter Drawn Arc Stud Welding CD Stud Welding
1/16″ to 1/8″ Not effective Effective with standard procedure
1/8″ to 1/4″ Limited applications Effective with standard procedure
1/4″ to 1/2″ Effective with standard procedure Effective with specialty procedure
1/2″ to 1″ Effective with standard procedure Not effective
1″ to 1 1/4″ Limited applications Effective with standard procedure
Over 1 1/4″ Effective with standard procedure Not effective

 

Stud Material Drawn Arc Stud Welding CD Stud Welding
Carbon Steel Effective with standard procedure Effective with standard procedure
Alloy Steel Effective with specialty procedure Limited applications
Stainless Steel Effective with standard procedure Effective with standard procedure
Aluminum Effective with specialty procedure Effective with standard procedure

 

Base Material Drawn Arc Stud Welding CD Stud Welding
Carbon Steel Effective with standard procedure Effective with standard procedure
Alloy Steel Effective with specialty procedure Limited applications
Stainless Steel Effective with standard procedure Effective with standard procedure
Aluminum Effective with specialty procedure Effective with standard procedure

 

Base Metal Thickness Drawn Arc Stud Welding* CD Stud Welding**
Under 0.015″ Not effective Effective with specialty procedure
0.015″ to 0.062″ Not effective Effective with specialty procedure
0.062″ to 0.125″ Limited applications Effective with standard procedure
Over 0.125″ Effective with standard procedure Effective with standard procedure

*Base metal thickness should be at least a third of the weld diameter for best strength.

**Base metal thickness should be a minimum of 0.020″ to prevent weld melt-through.

 

No matter what type of stud welding specifications you are working with, NFS can supply a comprehensive range of tools, studs, accessories, and other stud welding equipment. To learn more about standard, specialty, and limited processes for drawn arc and CD stud welding, contact NFS at (651) 730-7770. Request a quote online to get started with us today.

 

 

 

 

 

 

 

NFPA 70E Electrical Standards for Stud Welding

Like any other aspect of the commercial manufacturing industry, stud welding has its own set of regulations. Stud welding practices, tools, and materials are all regulated in certain ways to U.S. and worldwide standards. In addition to the regulations specific to stud welding, there are universal standards for all types of welding, including electrical specifications according to the National Fire Protection Association (NFPA) and the National Electrical Code (NFPA 70) the NFPA outlines.

 

If you’re working with stud welding tools, understanding the regulations of the NFPA and general electrical standards can be a key part of the job. At Northland Fastening Systems, our expert technicians can provide guidance, and our primary role as a stud welding supply shop offers a comprehensive range of tools for rent or purchase, studs in many dimensions, and stud welding accessories.

 

In the U.S., the NFPA covers a broad range of regulations for electrical situations depending on the location, purpose, and general circumstances. When it comes to electrical safety in the workplace, especially in terms of a manufacturing setting, the NFPA 70E regulations detail the exact specifications facilities need to meet.

 

The goal of the NFPA 70E standards is to “provide a working area for employees that is safe from unacceptable risk associated with the use of electricity in the workplace.” To reach this goal, a broad range of workplace specifications must be met, but generally speaking, it addresses the following:

 

  • Electrical conductors and electronic equipment installed inside buildings and other structures or installed on those structures
  • Conductors that connect those installations to a power source

 

While the NFPA 70E also covers numerical specifications concerning voltage, hertz, heat, conductivity, calories/cm2, and other properties of electrical systems, it also includes more general regulations for the workplace. For example, designating a safe work zone with proper signage, warnings, and distancing precautions is a significant part of any stud welding site. Setting standards that take into account sparking, shielding gas, and personal protective equipment are also key to the NFPA 70E.

 

Overall, most stud welding technicians have a strong grasp on safety measures, and many welding units take into account electrical issues like surges. If you’re working with any NFS tools and equipment, you’re using high-quality stud welding products that will not have any electrical problems when used properly. NFS provides state-of-the-art tools through our rent or buy options, our studs can be custom made to fit your exact specifications, and all our experts are just a phone call away.

 

To get started with Northland Fastening Systems on your project today, contact us at (651) 730-7770 or request a quote online.