Month: April 2021

Integrating an Automated Stud Welding Process

Posted on by norfas by norfas

Stud welding operations are streamlined, quick processes that allow technicians to install a broad range of stud types in many applications with powerful connections and clean finishes. Even handheld welding guns and lightweight or portable units can increase production speed and improve results. However, with an automated stud welding process installed in your production line, you can greatly increase the speed and quality of your welding operations while eliminating unnecessary costs and material waste. At Northland Fastening Systems, we offer a complete range of supplies for any stud welding process, automated or not. We provide a large collection of studs in varying dimensions and materials, welding tools for rent or purchase, welding accessories, and the expertise of our own technicians for advice or tool services.

 

If your production schedules have expanded to the point of considering integrating an automated stud welding process into your facilities, there are a few things to consider to determine if a fully automated system is the right choice.

 

  • Production: The main thing to consider before automating is if your production output and operation types fit an automated rate and facility set up. When automating the stud welding process, you will also have to increase assembly speeds. Consider the bottle necks for assembly in your facility and workers. Analyze your current production cycle time and determine where parts of the assembly process that won’t be automated can be sped up.

 

  • Safety: Worker safety should always be considered before making changes to your facility. When installing an automated system into existing facilities, the effects of that integration should be diagnosed before moving forward. Consider ergonomics, torque, tool weight, operator fatigue, and more. Make sure everything fits together correctly, and provide extensive training and safety procedurals to workers whenever new equipment is introduced.

 

  • Quality: Finally, you need to ensure that installing an automated system for your stud welding process won’t compromise quality in any way. If an automated system will change products in any way, the assembly process must be altered to fit those changes. Stud installation should be done with perfect accuracy if your automated system is properly functioning. Collect data before and after installing an automated system and compare to see improvements, or lack thereof, in quality.

 

Working with highly rated, expert providers like Northland Fastening System will help you find the right automation options and install new equipment successfully. We offer user-friendly, effective automation options for drawn arc, CD, and short cycle welding. To learn more about our automated equipment for the stud welding process, contact Northland Fastening Systems at (651) 730-7770. Request a quote online to get started with us today.

Part Two: Shielding Gas and Its Role in the Stud Welding Process

Posted on by norfas by norfas

In the first part of this two-part blog, we covered the use of shielding gas in arc stud welding and the role it plays in helping to form a strong weld. Shielding gas essentially protects a weld point from exposure to potential contaminants like oxygen and moisture. With shielding gas, welders can eliminate potentially porous welds prone to corrosion. In the stud welding industry, shielding gas is typically used with drawn arc welding to replace the need for a flux and ferrule ring system. If you’re working with the stud welding process for any project, Northland Fastening Systems can provide any tools, studs, and welding accessories you might need, in addition to the expert advice of our own staff of stud welding technicians. As a comprehensive supplier for the stud welding process NFS has what you need for drawn arc, CD, and short cycle welding.

 

There are several types of shielding gas available to the welding industry, varying in price, production capabilities, and overall effectiveness. Choosing the right shielding gas for your stud welding process depends on your budget, desired finished properties of your weld, welding materials, pre- and post-weld cleanup abilities, and production schedule.

 

There are four common shielding gas types used in most welding processes: carbon dioxide, argon, oxygen, and helium.

 

  1. Carbon dioxide: The most common and least expensive shielding gas on the market, CO2 is the only gas that can be used in pure form without inert gas added. CO2 also helps to achieve a deep weld on thicker materials. However, it can create a low stability arc resulting in spatter when other gases are added, and it’s only useful in short circuit operations.
  2. Argon: The results of using an argon shielding gas are generally considered the best quality, both cosmetically and functionally. A mix of 75 to 95% argon with 25 to 5% CO2 is an ideal ratio for arc stability, minimal spatter, and a controlled puddle. Argon can also increase production rates with a spray transfer technique. Although argon is an abundant resource, it’s slightly more expensive than other shielding gases because of the difficult containment process.
  3. Oxygen: When used in small ratios, oxygen can help control fluidity of weld puddles, penetration, and arc balance. Oxygen is useful for mild carbon and stainless steel, but it can cause oxidation in aluminum, magnesium, copper, and other metals.
  4. Helium: Used with argon in similar ratios as argon/CO2 mixes (25% helium to 75% argon), helium provides deep penetration. Ratio adjustments offer control of arc heat/travel speed and increased productivity. Helium is also generally used in a mix of argon and CO2. Overall, helium is on the pricey side so it’s often added in as small amounts as possible.

 

Choosing the right type of shielding gas will go a long way in supporting quality weld results and increasing your production schedule. To learn more about the stud welding process and the complete line of supplies we offer, contact Northland Fastening Systems today at (651) 730-7770 or request a quote online.

 

Part One: Shielding Gas and Its Role in the Stud Welding Process

Posted on by norfas by norfas

In many manufacturing industries, stud welding is often relied upon for its ability to create powerful fastening systems quickly and cleanly. The industries that the stud welding process is utilized in range from food grade manufacturing to composite large-scale construction.

 

As a type of arc welding, the stud welding process is capable of forming connection points that are stronger than the stud or base material. There are several types of stud welding processes, including drawn arc, capacitor discharge (CD), and short cycle welding.

 

At Northland Fastening Systems, we provide a comprehensive supply of tools, studs, and accessories for each stud welding process as well as the expert advice of our own technicians.

 

Compared to other types of arc welding, stud welding is a relatively straightforward process with few bells and whistles required to perform a strong weld. For example, technicians performing other welding processes require significant personal protective equipment and often shielding gas, slag, vapor, or other weld protective measures must be taken. The stud welding process is designed to be performed rapidly, easily portable in the field, and require only basic training for the welding technician.

 

CD and short cycle welding in particular are streamlined, fast operations compared to many other welding techniques. However, they are only suitable for a “lightweight” range of duties and are limited to smaller studs and overall moderate applications. Drawn arc welding, on the other hand, can be used in large-scale applications like composite construction for bridges and buildings. Because drawn arc welding utilizes additives like shielding gas and ceramic ferrules that other arc welding processes use for various operations, it’s capable of installing larger studs and heavy-duty manufacturing.

 

Typically, drawn arc welding uses a ceramic ferrule ring to contain the heat generated at the weld point and a flux tip to control the melt temperature. Using these additives in the stud welding process helps control the fusion and create a clean weld result. Welders can also use shielding gas in the place of a ferrule ring.

 

Shielding gases like argon, carbon dioxide, and helium are inert, and when applied during the welding process will protect the weld from air contaminants like water vapor and oxygen that would otherwise create a porous weld prone to cracking and corroding. When applied in a drawn arc stud welding process, shielding gas also helps control the arc, prevent splatter, vary penetration depth, and more.