Automated Production Stud Welding Machine Rundown

When used correctly, stud welding is a highly efficient, powerful, and flexible operation in any application. From handheld, portable welders for operating on multiple job sites to fully automated production welders integrated into a facility, stud welding creates long-lasting connection points in many conditions, and it’s a critical component in most steel and concrete composite constructions. At Northland Fastening Systems (NFS), we support all kinds of drawn arc, short cycle, and capacitor discharge stud welding operations with a complete range of supplies. Not only do we provide welding studs in a broad range of dimensions with custom sizing options available, we also have tools for rent or purchase, and a variety of welding accessories. In addition to a quality selection of portable and handheld welding tools, we also provide effective solutions for automated production stud welding machines.

Production Welders

Production welders are computer numerical control (CNC) automation systems that have a range of structures. Some welders have single-head, hand-loaded welders, while others are fully automated, multi-headed welding systems. Any automated stud welding machine can be integrated into a facility to streamline the production line, increase output, and improve precision.

Stud Welding Machine

If you’re ready to integrate new automated welding systems into your production floor, you can choose from several options, for example:

  • PAH-1: This handheld stud welding gun is automatically fed studs for a rapid-fire range. The PAH-1 is best suited for contact, gap, or short cycle welding on thin sheets at least 0.5 mm in thickness. This lightweight gun is ergonomic and adjustable with convertible stud lengths. For fast, electronically-controlled welding on thin materials, this is an ideal automation choice.
  • PC-S: The PC-S (Production Center Standard) performs all types of stud welding with manual or automatic stud feeding. Its handling systems are customized to your needs, and it has a short setup time. The PC-S is controlled with a microprocessor for extreme precision, and its protected work plate holds up to wear and tear. For versatility and accuracy, the PC-S is a great investment.
  • CPW 0604: This CNC production welder uses tip ignition, drawn arc, and short cycle welding systems and shielding gas modules for a broad range of fully automated applications. It saves costs and time, and it’s one of our most user-friendly tools. The setup for CPW 0604 welding is quick and easy, and the work system’s precision has long-term reliability. For exact welding applications with shielding gas in a controlled environment, the CPW 0604 CNC tool is a quality selection.
  • MPW 1010/2010: For full bench automation and CNC multi axis production, the MPW 1010/2010 is a high-powered, heavy-duty tool. In addition to most variants of stud welding, it also performs simple CNC milling. This bench tool is one of our most high-powered, fully automated systems with programmable sequences and control of all welding details.

To learn more about our other options for an automated stud welding machine, contact NFS at (651) 730-7770 or request a quote online.

Construction Welding and Shear Connector Facts

One of the main reasons why composite construction holds the strength it does for applications like road, bridge, and building fabrication is because of stud welding. Stud welding with shear connectors and bar anchors allows workers to connect concrete to steel beams and other girders. For most large-scale construction projects, composite construction is a key component of building with accurate, durable, and long-lasting designs. For any stud construction welding needs, Northland Fastening Systems (NFS) has the supplies to get the job done. From studs in a complete range of dimensions and custom options available to welding tools for rent or purchase, NFS is a comprehensive resource for stud-welding supplies. In addition to a full range of tools, studs, and accessories, our welding technicians can provide tool repairs and give guidance for best practices in whatever you’re working on.

Stud Welding in Construction

Stud welding in composite construction is performed with drawn arc operations to install fasteners that form structural connections between steel beams and concrete slabs. Most applications can hold loads up to 1,000 kg/m², which is much higher than composite applications that don’t rely on stud welding.

Shear Connectors

Shear connectors are the most critical component of a composite construction when bonding concrete and steel beams. They completely impact the effectiveness, ergonomics, speed, stability, and safety of a composite construction. In hindsight of examining bridge collapses, severe road damage, and other failures, we’ve determined that the correct application or use of shear connectors often could have prevented the incident.

Construction Welding

When using shear connector studs in construction welding, drawn arc currents range from 240 to 3,000 amps and a ceramic ferrule is used to prevent issues like splatter, burring, slagging, and brittle welds. Shear studs are typically low-carbon steel, but they can be applied in stainless steel when protection from corrosion is necessary. When welded, the length of a shear connector is reduced by about 5 mm.

Stud Welding in Composite Construction

The reason why the incorporation of stud-welding techniques in composite construction is so effective is because the installed studs resist shear force. Shear force runs parallel to the cross section of a road, bridge, or other composite structure. That impact creates significant strain on inflexible construction, but longitudinal shear connectors allow the concrete and beam composite to bend and resonate with the stress, increasing durability.

Installation of Shear Connectors

The correct installation of shear connectors prevents the concrete slab from separating from the steel beam as they both bend from stress. Shear connectors should be installed on a clean deck surface free of paint, dust, oil, and water. Ceramic ferrules can be left to be covered by the concrete pour, but the pour should significantly cover the tops of the studs. Some beam areas may require additional reinforcing depending on the shallowness of the decking and the region along the composite construction.

To learn more about using shear connectors in construction welding, contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.






Application of Different Metals for Welding Studs

Welding is one of the oldest metalworking techniques we still use today. Forge welding dates back to the Iron Age, around 1200 BCE. Since then, many kinds of welding have been developed, and each effective welding operation used across many industries today is highly precise, versatile, and reliable. Stud welding is one of those operations that’s used to install fastening systems, composite construction, and other fabrication techniques. If you are utilizing drawn arc, capacitor discharge (CD), or short cycle stud welding, Northland Fastening Systems has the supplies you need. We also offer a comprehensive range of stud welding tools for rent or purchase, welding studs in varying dimensions with custom options available, welding accessories, and the expertise of our own stud welding technicians. Additionally, we provide repairs and services for the majority of stud welding equipment models, including HBS, Tru-Weld, ProWeld, Nelson, and more.

Uses for Stud Welding

No matter what type of stud welding operation you are using, there is likely a plethora of applications. Stud welding is frequently used in sheet metal construction, food-grade welding, electrical enclosures, composite construction, and more. Its range of uses is in part due to the versatility of the welding operations themselves, but also because there are multiple metals that are conducive to the stud welding process.

Metals Used With Welding Studs

Both the welding studs and the surface material can be made from a range of metals, including:

  • Steel: The most prevalently used metal for stud welding is steel. Low, medium, and high-carbon steel can always be used in stud welding operations. This is also the case for stainless steels, but other steel alloys should generally be avoided in stud welding processes. Low-carbon steels do not require pre-heating, but medium- and high-carbon surfaces (anything above 0.25% carbon by weight) do need pre-heat treatment to prevent cracking.
  • Aluminum: Secondary to steel, aluminum and aluminum alloys are also effective materials for welding studs and surface materials. While alloys are useful, pure aluminum is generally the more preferable material for stud welding.
  • Brass: If lead-free, brass can also be used as a stud welding material. In situations when steel or aluminum cannot be applied for various reasons, brass is usually the alternative material. CD welding operations are most suitable when using brass studs and surfaces.
  • Copper: In some circumstances, copper has great advantages as a welding material. Copper is usually used with CD stud welding when a project needs to be mark-free or when electrical conduction is a factor. For mark-free copper surfaces, brass studs are the best pairing and installation should be performed with rapid CD operations.

While stud welding is relatively limited to these four base materials, there’s a huge range of alloys and types within these different metals. With the right application, stud fastening systems are extremely strong, long-lasting, and flexible.

To learn more about the materials used for welding studs and the equipment and supplies we offer for stud welding operations, contact Northland Fastening Systems at (651) 730-7770. Request a quote online to get started with us today.