The Importance of the Stud Welding Process in the U.S. Navy from WWII to Today

For years, the stud welding process has been used for fabrication of all kinds of large-scale construction projects, including a high prevalence and cruciality to the shipbuilding industry. Despite the importance and well-documented use of stud welding in the maritime industry today, it wasn’t always such a highly prominent fabrication process. In fact, it wasn’t until the U.S .Navy’s use of stud welding during World War II (WWII) that the world began to recognize the stud welding process as a superior manufacturing operation for stronger, faster, lighter, and longer-lasting ships. Whether you are a player in the maritime industry or are working on a smaller scale project, Northland Fastening Systems has everything you need to complete the stud welding process from start to finish, including stud welders, studs, accessories, and our own stud welding services.

 

Stud welding was one of the most important manufacturing processes for shipbuilding and the U.S. Navy in WWII. Although stud welding was commonly used in shipbuilding since the early 1900s, the results were still creating warships, freighters, and other large vessels that were heavy, slow, and required an excess of materials. By the 1930s, the United States realized it needed a strong marine and naval force to protect the country.

 

In the face of the war and a lackluster maritime presence, the U.S. Congress passed the Merchant Marine Act in 1936, which helped both U.S. merchant ships and the U.S. Navy revolutionize their maritime presence, almost completely thanks to the act’s requirement of improved ship construction. To meet this requirement, a stud welding technique that the American Welding Society and the New York Navy Yard developed in 1930 was vital.

 

This stud welding technique provided a way to connect wood directly to steel. The new ships built in accordance with the Merchant Maritime Act relied heavily on this technique and other stud welding processes to build ships unparalleled by any other navy at the time. In many ways, stud welding helped the United States and its allies win WWII.

 

Since the use of stud welding processes in shipbuilding during WWII, naval and merchant vessels have benefited from huge advancements in welding units, welding guns, studs, and other stud welding techniques. Even today, with the range of futuristic manufacturing capabilities, stud welding is a staple for maritime industries.

 

To learn more about the use of stud welding processes in shipbuilding and many other industries, or to get the supplies you need, contact Northland Fastening Systems at (651) 730-7770 or request a quote online today.

Old and New Uses of Stud Welding Equipment in Shipbuilding

The use of stud welding for shipbuilding and other maritime construction is as old as the welding process itself. As far back as the turn of the 19th century, simple forms of stud welding were developed for various shipbuilding purposes.

 

By the end of WWI, stud welding began to play a more significant role for industrial shipbuilding of trade and military vessels. Many wars and technological advancements later, stud welding remains a primary manufacturing operation for shipbuilding large and small. Northland Fastening Systems provides a wide range of reliable, high-quality stud welding equipment suited for any type of shipbuilding projects and other construction welding.

 

From portable automated welding units to highly specified welding studs, NFS has everything you might need for even the largest shipbuilding project. The history of shipbuilding was revolutionized by the development of stud welding procedures suited to the fabrication of seaworthy vessels and other marine components. Today, both drawn arc and CD stud welding are used in a wide range of shipbuilding operations. Some of the most prevalent of these operations include:

 

  • plating hulls and protecting or streamlining other exteriors
  • building decking, bulkheads, and other interior structures
  • fittings including portholes, hatches, or storage units
  • pipe and cable hangers and protection units
  • manhole fittings, winches, ladders, and other functional accessory components
  • propellers, rudders, steering shafts, masts, and other locomotive components
  • connecting lining and wedging joints, anchoring equipment, shell plating, and ceramic backing
  • performing repairs at sea

 

In a nutshell, a broad majority of shipbuilding operations rely on stud welding. Technicians working on shipbuilding projects can find all the stud welding equipment they need with Northland Fastening Systems. Our stud welding technicians provide CD and drawn arc welding services and guidance, and we offer stud welding equipment including stud welding units and welding guns for sale or rent, welding studs for CD and drawn arc welding in a variety of metals, sizes, and other specification, and any other stud welding accessories you may need.

 

Stud welding operations used in shipbuilding and maritime manufacturing contributes to the construction of small boats for personal use, small to large boats for police, forestry, and coast guard purposes, long-haul freighters and milk truck delivery boats, submarine research vessels, pleasure cruise ships, armed military vessels, aircraft carriers, and many other types of sea and freshwater ships.

 

To learn more about the use of stud welding for shipbuilding and other marine construction purposes, contact Northland Fastening Systems at (651) 730-7770, or to find out more about the stud welding equipment we offer, contact request a quote online.

Suitable Materials for Welding and Finding What You Need with NFS Stud Welding Supplies

Metalwork is one of the most important methods of manufacturing for a wide range of construction and production industries. As a part of metalworking as a whole, stud welding has its own place of import in many types of fabrication. From metal equipment manufacturing of all kinds to large-scale construction, stud welding is utilized in the fabrication of many shapes and sizes. If you are working on a project that requires the use of stud welding for clean, quality building, Northland Fastening Systems (NFS) is your one-stop shop for quality stud welding equipment, including tools for rent and purchase, studs fitting all size, thread, and material needs, and stud welding accessories. As a leading industry provider of stud welding supplies locally and globally, NFS has what you need for any project, no matter how complex.

 

While the material used in welding is most often a steel composite, there is a wide variety of additional alloys that are effective for many welding circumstances. From aluminum to copper, stud welding can be performed with several different quality materials.

 

Stud Welding Metals

 

  1. Stainless steel: One of the most commonly used stud materials, stainless steel offers a greater resistance to corrosion. Stainless steel studs are also highly durable and can take many finishing and treatment applications, such as annealing or plating. Both drawn arc and CD stud welding studs can be made from stainless steel.
  2. Mild steel: Also suitable for both drawn arc and CD stud welding, studs made from mild steel alloys are available with a range of properties. Alloys can be made for greater heat resistance, strength, durability, corrosion resistance, acid resistance, flexibility, and more.
  3. Aluminum: Aluminum studs are useful when welding to aluminum bases. NFS offers studs made from aluminum alloys for CD stud welding with options for three different alloy compositions. These alloys vary in properties and provide different fits for different projects.
  4. Brass: CD stud welding can also utilize brass studs. These lead-free brass studs can be welded to a similar brass alloy base or to a lead-free copper alloy base.
  5. Copper: While not typically used as a material for the stud alone, copper can be key when used to plate a CD welding stud. NFS offers copper plating as a standard option for low-carbon steel studs to improve thermal and electrical conductivity from stud to surface.

 

No matter what project you need stud welding to complete, NFS has the stud welding supplies compatible with your welding tools and the base materials you need to weld. Specifications for materials, length, diameter, threading, flanging, plating, annealing, and more are all available to customize your order to the perfect fit for your fabrication requirements.

 

To learn more about the materials and other stud specifications we offer, or to learn about the stud welding tools, welding guns, accessories, and other stud welding supplies Northland Fastening Systems provides, contact us at (651) 730-7770. You can also request a quote online to get started working with us today.

 

Physical Effects of Stud Welding and the Advantages of Automation

Stud welding is a fabrication technique that is critical to a wide range of manufacturing industries. Not only is it used in equipment manufacturing of all shapes and sizes, it’s also an important part of building construction and other large structures. Because of the immense prevalence of stud welding in the industrial world, it’s important to have access to quality stud welding equipment, studs of all dimensions and materials, and comprehensive accessories. That’s why Northland Fastening Systems provides everything fabricators need for their stud welding projects and services.

Stud welding, though an effective and widely versatile fabrication method, requires a lot of repetitive motions. Technicians often perform more than 1,000 welds in one day on the job, and the repeated motions involved in the process can take a physical toll. However, this effect is not the only impact that welding technicians experience with long-term stud welding work.

 

Impact of Prolonged Stud Welding

Stud welding technicians are exposed to two types of potential physical harm:

  1. Physical stress from the bending motions of welding many studs repeatedly
  2. Various health risks from the fumes created in the welding process

Of these two, the fumes created with each stud weld operation is an issue addressed less often than it should be. The heat and pressure of both drawn arc and CD stud welding operations creates a plume of respirable metalloid particles small enough to be forced into a radius of approximately 12-20 inches. These plumes can contain zinc, nickel, iron, copper, manganese, chromium, cobalt, lead, and more, depending on the welding materials.

Many welding technicians wear little-to-no breathing protection, and because of this may be at greater risk for lung cancer, metal fume fever, pneumonia, and bronchitis. Some studies have also shown that welders exposed to welding fumes over extended periods of time may be at greater risk of developing Parkinson’s disease. Despite this danger, there are many ways to minimize the potential of physical damage from the fumes and the welding process itself.

 

How Automation Can Protect Your Welders

Automated stud welding offers many solutions for preventing or limiting health risks and physical long-term effects many welders experience. NFS offers automation capabilities that can change the way your welding technicians perform their tasks. Stud welding units that are automated can greatly reduce the need for technicians to perform repeated physical movements to establish a weld connection. Automation also often removes the welding technician’s breathing zone from the dangers of the welding plume. Limiting the exposure to fumes and the time spent performing repetitive motions can significantly reduce physical harm to your stud welding technicians. NFS provides a wide range of automated stud welding equipment, including units that can withstand harsh environments.

 

Protecting your workers and streamlining your stud welding production starts with automation. Get started with Northland Fastening Systems today and contact us at (651) 730-7770 to learn more about minimizing the health risks of stud welding and the benefits of automation.

Fabricating Clean Electrical Enclosures with Quality Stud Welding

Northland Fastening Systems (NFS) utilizes the capabilities and benefits of stud welding operations for a wide range of manufacturing purposes. We also provide stud welding services for a variety of industries, offer stud welding tools for rent and sale, and sell a comprehensive assortment of studs and accessories.

Because of the versatility stud welding offers in so many fabrication processes, it’s a valuable option for many projects, big or small. With our variety of products, tools, and stud welding services, NFS is a fully outfitted provider for all stud welding manufacturing requirements in the U.S. and worldwide. If you’re looking to get started on your stud welding and need direct access to all you need at one friendly location, look no further than NFS.

The range of different applications that stud welding is suited to casts a wide net over industrial and small-scale manufacturing. When it comes to fabricating components for electronics, stud welding is a primary source for manufacturing durable, specialized electrical enclosures.

 

What are Electrical Enclosures?

Electrical systems are powerful tools for many purposes, from directing and storing current to computing the trajectory of a space shuttle. Despite their powerful capabilities, electronics themselves are often fragile systems with little defense against liquids, extreme temperatures, lights, and many other stresses. Because of their vulnerability overall, electrical enclosures are critical components in the majority of systems.

Electrical enclosures are essentially cabinet units that protect and store electrical systems. They can range from simple box units made from aluminum to ruggedized, highly durable enclosures built with weather-resistant alloys. Enclosures can be standardized to a specific range of electrical setups or they can be specialized to a fit a uniquely designed electrical unit.

For all types of electrical enclosures fitting all types of electrical systems, stud welding is an extremely useful method of construction for several reasons:

 

  1. Stud welding creates a clean weld without a mark on the surface opposite to the weld
  2. Using high-quality studs and welding tools creates a strong weld connection
  3. Certain stud types can be fabricated for controlled conduction of electricity
  4. Welds can be created on the interior of an electrical enclosure for a clean, mark-free exterior
  5. Stud weld connections bind greater areas of a surface than other types of welding
  6. Enclosures made with stud welding can be fabricated with a wide range of materials
  7. Stud welding offers a rapid build process without sacrificing quality

 

For any size or shape of electrical enclosure, stud welding is a great choice for a clean, seamless, finished look. To learn more about the capabilities of stud welding beyond manufacturing high-quality electrical enclosures, contact Northland Fastening Systems at (651) 730-7770 or request a quote online.

Breaking Down the Process of Quality CD Stud Welding

Northland Fastening Systems provides high-quality stud welding services, stud welding tools for sale and rent, and every stud welding accessory you need to get the job done. From food-grade welding to structure-strength sheet metal welding using both drawn arc and capacitor discharge (CD) welding, NFS has the right equipment for the job.

 

Because stud welding is such an efficient, effective, and powerful tool in a wide range of industries, it’s one of the most critical operations in many fabrication projects. Both drawn arc stud welding and CD stud welding have a foundational use in different types of welding projects, but more and more technicians are utilizing state-of-the-art CD welding units for rapid welding purposes.

 

CD stud welding is, for all intents and purposes, a form of arc welding. In comparison to drawn arc stud welding, however, it’s much faster, performing a pre-calibrated weld in milliseconds that leaves little-to-no mark on the opposite side of the weld surface.

 

CD Stud Welding Step by Step

With the right tools, performing CD stud welding is a straightforward process for welders of all skill levels. Most CD welding units offer pre-programmed settings for a weld cycle, or simplistic ways of calibrating a preset voltage depending on the stud materials and size as well as the material of the weld surface. The process goes as follows:

 

  1. The stud welding unit is calibrated to suit the situation.
  2. A stud is loaded onto the gun tip.
  3. The stud welding gun is positioned at the desired weld point.
  4. The welding operation is triggered, sending energy stored in the capacitors to be discharged onto the stud in a semi-automatic arc.
  5. The heat of this energy essentially vaporizes the tip of the stud and creates an ionization path.
  6. The path opens up a full flow of current arcing across the stud and melting the metal of the stud tip.
  7. Pressure from the welder then forces the molten tip of the stud onto the weld surface.
  8. This pressure and the cooling metal forms a strong bond between the stud and the weld surface.

 

CD stud welding doesn’t use a ferrule like its cousin, drawn arc stud welding. This means the weld is performed much more quickly, but the nature of the weld limits the size of the stud. CD welding is suited to stud diameters from 14 gauge up to 3/8”, there are no limitations on stud length. Materials that can be welded using CD stud units include stainless steel, mild steel, brass, and aluminum. Although CD stud welding is not the best choice for heavy-duty purposes, it has a prevalent use in smaller scale, rapid, efficient production. Its weld connection is stronger than the stud material itself, and it can be more easily automated than other types of welding.

 

To learn more about CD stud welding  and the services or products we provide that are fitted to that operation or others, contact Northland Fastening Systems at (651) 730-7770 or request a quote today.

Stud Welder Profile: The HBS CDi502

No matter what stud welding project you’re working on, there’s a welder and the accessories that will fit your needs, and all those tools can be found at Northland Fastening Systems. NFS provides stud welding services, tools for rent and sale, and every type of stud, pin, bar anchor, and accessory you could ask for. We are your one-stop-shop for all things stud welding, and we only stock the most highly-rated welding tools and the best-made stud accessories.

If you’re in need of a stud welder for faster, more efficient, higher quality, and cost-effective production, NFS is here to help. With a variety of HBS and TRUWELD brand stud welders for sale, you’re sure to find a welder that meets the specifications you need. For beginner stud welders, we can work with you to find a few options that will be good fits. For example, the HBS CDi502 stud welder is an easy-to-use, quality unit for entry level CD stud welding.

The CDi502 is one of the best welders for those with minimal expertise in the application of CD stud welding on any given project. Its pre-programmed settings make it perfect for beginners, but it’s also a great option for welders of all skill levels.

 

Benefits

  1. Lightweight and portable
  2. Easy to use
  3. Quick recharges thanks to its inverter capacitor charging technology
  4. Extended performance cycle
  5. Compact casing sized at 10.12” x 6.42” x 14.29”
  6. Spring force welding gun that does not requires adjustments
  7. Suitable for a range of materials

 

Specifications

  1. Welds aluminum, stainless steel, and mild steel
  2. Performs rapid 1 to 3 millisecond capacitor discharge welds
  3. 100v to 240v
  4. Single phase
  5. 50/60 Hz
  6. 500ws
  7. Welds steel at #4 to ¼”
  8. Welds aluminum at #4 to #8
  9. Weighs 21.83 lbs.
  10. Temperature-controlled fan
  11. Welds 10 studs per minute
  12. Outputs 100,000 μF capacitance
  13. Recharges at 50v to100v

 

The German-made HBS CDi502 is a versatile, compact, and easy-to-use stud welder perfect for movement between job sites. If you think this welding unit is right for your projects, we can give you the guidance and direct information you need to get started with it today. Simply request a quote online, or contact us at (651) 730-7770 to learn more.

 

If you’re looking for a drawn arc welding unit or another type of CD welder, NFS has tool options meeting a wide range of specifications. Find out more about the stud welder you need through our online store, or by contacting us directly.

 

Understanding the Process and Benefits of Short Cycle Stud Welding

The various types of stud welding can be utilized in a broad range of manufacturing applications, and they cover quite a comprehensive amount of parts and components. From electrical enclosures and small-scale food industry equipment to construction equipment and sheet metal manufacturing, stud welding has an essential production use. When you partner with Northland Fastening Systems, you have access to our complete stud welding services as well as the tools, equipment, and accessories we provide. For both drawn arc stud welding and CD stud welding, you can trust NFS to meet all your needs with quality service and products.

 

When it comes to differentiating and understanding the types of stud welding we provide services and equipment for, there are a few points to take into consideration:

 

  1. Drawn arc stud welding utilizes a different welding process than CD stud welding. Learn more about the differences from this NFS blog post.
  2. CD stud welding is often more suited for welding thinner materials without leaving a mark on the reverse side of the weld spot.
  3. Drawn arc stud welding is more suited to welding heavier materials with wider weld spots allowing structural strength.
  4. CD welding is faster and requires less energy than drawn arc stud welding.
  5. Drawn arc welding is stronger than CD stud welding, and it can be used in large-scale construction applications.

 

NFS offers studs and other accessories for all types of stud welding including a variant of drawn arc stud welding called short cycle welding. Short cycle welding is a kind of drawn arc stud welding that can be performed faster than the standard process and is somewhat of a compromise between drawn arc and CD stud welding.

 

Here’s how it works:

 

Unlike typical drawn arc stud welding, short cycle welding does not use a ceramic ferrule to contain the molten metal at the weld point. Short cycle welding is performed by creating a pilot arc that melts the end of the stud and then connects the stud to the base material using pressure between the base and stud alone. This weld occurs in 10-100 milliseconds and can use CD studs depending on the welding circumstances. Basic necessities for the application of short cycle welding include:

 

  1. Three-phase and 480-volt power supply
  2. Threaded CD studs like those offered in the NFS store
  3. A base material thicker than 1.7 mm at minimum

 

The benefits of short cycle stud welding are many when used in the correct application. Short cycle welding is faster, uses lower-cost equipment, provides a higher tolerance weld point on irregular or coated base materials, and is often more convenient than typical drawn arc or CD stud welding. Short cycle stud welding is also more easily automated than other stud welding operations.

 

To learn more about short cycle stud welding and other stud welding processes, contact Northland Fastening Systems at (651) 730-7770, or request a quote to get started in a partnership with us today.

 

 

Why Food-Grade Welding is Widespread Throughout the Common Commercial Kitchen

From restaurants to hospitals to food trucks and beyond, every commercial kitchen utilizes a wide range of stainless-steel products. Because stainless steel is highly resistant to corrosion, acid damage, and other concentrated substances that often show up in kitchens, it’s the most logical choice of material for many components in commercial settings. The production of these stainless-steel kitchen products is most efficiently completed with stud welding processes. At Northland Fastening Systems, food-grade welding capabilities are just a click away with our stud welding services, tool rentals, and available equipment and accessories.

 

The efficiency and practicality of stud welding stainless steel for food-grade welding products is the primary reason why the demand for such a wide range of these kitchen components is so prevalent. Many other materials will rust, allow mold growth, start to degrade, and otherwise pose unhealthy working conditions and food production sanitation.

 

With the rapid welding process and strong connection points stud welding gives manufacturers of food-grade products, it’s not uncommon to see a variety of kitchen components in a commercial setting including:

 

  1. Stove units made with stud welded stainless-steel sheeting that holds up to the flames, grease, and other stresses in a commercial kitchen.
  2. Stainless-steel cased ovens that hold up to constant heat throughout the day and long-term use of that daily capacity.
  3. Shelving units that must support up to 2,000 lbs. regularly while exposed to temperatures ranging from walk-in freezers to heat from adjacent stoves and ovens, in addition to grease and moisture exposure.
  4. Tables and counters that hold up against continual exposure to acidic foods and liquids, knives, abrasive cleaning fluids, pounding, heavy weights, grease, heat, and cold.
  5. Heavy-duty kitchen ventilation systems and stove hoods that filter out highly acidic smoke, heavy-duty grease, and moisture constantly throughout the working day while often withstanding high heat from stovetops.
  6. Sinks and plumbing systems that take on grease, food, hair, dirt, and more in the day-to-day business of a commercial kitchen.
  7. Coolers and refrigerators that are subjected to constant opening and closing, food spills, moisture collection, freezing water, and abrasive cleaning.
  8. Commercial dishwasher units that are continually exposed to water at high sanitary temperatures, grease, acidic foods, and harsh chemical soaps.

 

In addition to these common systems, there are many more components of a standard commercial kitchen made with stud welded stainless steel, including some more specialized products involved in food production (such as the beer and wine making processes) that are designed to hold up to severe daily conditions.

 

With the use of quality stainless steel and well-made stud welding studs like those offered at Northland Fastening Systems, you can create your own commercial kitchen components that hold up to harsh environments. Contact us at (651) 730-7770 to learn more about food-grade welding and the equipment and services we provide.

Using the Right Welding Studs for the Right Project

Stud welding is a highly effective process for forming strong connection points quickly and with a clean finish. However effective stud welding is, it’s not as effective as it could be if you’re using the wrong welding studs. There are several types of welding processes that require different studs, and understanding which studs are best for the weld gun, welding unit, and material you want to weld is key to successful production. Northland Fastening Systems provides a wide range of welding studs suitable for any project you need to complete.

 

From drawn arc stud welding to capacitor discharge stud welding, NFS offers welding services in addition to tools (available for rental and purchase), and of course, welding studs. No matter what format you need to fit your studs in, you can find what you’re looking for with NFS.

 

Common Welding Studs

 

Some of the most common welding studs that NFS offers that are suitable for a range of stud welding projects include:

 

  1. Flanged CD Studs: Made from stainless steel, aluminum, brass, or low carbon steel, flanged studs range in stud and flange diameter, thread, and length. Flanged studs can be annealed for durability and strength and plated in copper for heightened electrical conductivity.
  2. Non-Flanged CD Studs: Similar to flanged, non-flanged CD welding studs can be made from the same materials with the same annealing or plating processes. The difference lies in the size of the top of the stud. For a clean weld in applications where a flange would interfere with the materials being connected (often stud welding production with sheet metal), non-flanged studs are highly effective.
  3. Threaded Arc Studs: Both fully or partially threaded arc welding studs are made from mild steel or stainless steel and can be of varying thread size, length, and stud diameter. These studs can be used in applications where a peg stud has to protrude from the weld point (partial thread) or fully welded into a material (full thread).
  4. Anchor Arc Studs: Varying in stud length and diameter, anchor arc welding studs are made from low carbon steel or stainless steel. They are useful in forming peg studs of various lengths protruding from the weld point that offers a reliable, strong weight capacity.
  5. Bar Anchor Studs: Made from low carbon steel and available in a range of diameters and lengths, bar anchor studs are key in load-bearing production and provide a highly durable connection point.
  6. CD Welding Pins: Thin CD welding pins are made from mild steel and often have a copper plating to support conductivity. They create a nail-like point for lightweight support and connection useful in many building interior installation projects like, for example, installing insulation.

 

In addition to our range of welding studs, we offer quality goods and services in a pinch. Contact Northland Fastening Systems at (651) 730-7770 to learn more about our stud welding services and equipment.