Author: norfas

High-Integrity Thin-Gauge Connection Points with CD Stud Welding

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Early electrical capacitors date back as far as the mid-1700s. Those early rudimentary electrical charge storage systems developed over the next 250 years to the capacitors we use in many applications today. There are multiple variations of capacitors and supercapacitors used across contemporary industries that are highly advanced storage and release systems. Capacitor discharge technology is also utilized in stud welding applications for versatile, strong welds with thin base material. If you’re utilizing capacitor discharge (CD) stud welding systems, Northland Fastening Systems (NFS) has a comprehensive range of welding supplies, including tools for rent and purchase, studs in a range of dimensions with custom options available, welding accessories, and the technical support of our knowledgeable staff. There are many benefits that CD stud welding provides to manufacturers and technicians working with specific materials and small diameter studs.

CD Stud Welding

Not only does CD stud welding allow technicians to build with small diameter studs as, it’s also a manufacturing technique that allows work on thin-gauge welding surfaces without distortion. The ability to weld extremely small diameter studs onto thin surfaces without risking mark-through or structural distortion allows welders to install fasteners for a broad range of industries, including food-grade equipment and insulation. These processes help manufacturers build with integrity and meet specifications for unique products.

Dissimilar Metals

CD stud welding can also be used to fasten dissimilar metals like various steel grades, aluminum, copper, brass, and other alloys without compromising the strength of the weld surface or stud. This is because CD installation penetrates at shallow depths that don’t risk metallurgical issues.

With an ignition tip that is charged with the release of electrical current from a capacitor, CD tools generate a rapid weld with a clean, ideal cosmetic result. The process of CD stud welding done properly will have little-to-no burn marks, no marking on the backside of the weld surface, and a connection point even stronger than the stud itself.

Automated Production

When working with smaller diameter studs and thin welding surfaces, CD stud welding is also the most cost-effective for labor, materials, assembly, and energy in addition to being the most visually appealing. For components that can be installed in automated production lines, CD stud welding offers a rapid operation with precision on repeat.

High-Integrity Weld

CD stud welding creates such a high-integrity weld because of an exact calibration of heat and pressure. When the capacitor discharges its stored current and activates the ignition tip, the stud is heated and pressed into the weld surface at a specific pressure. The heat and pressure requirements depend on the diameter of the stud and the materials used. While contact CD stud welding is a more common process, some manufacturers will use gap welding tools. Gap welding is an effective operation when technicians who are working with aluminum and stainless steel require a completely mark-free back side.

To learn more about different CD stud welding operations, tools, and applications, contact NFS at (651) 730-7770. Or you can request a quote online to get started with us today.

Technical Details: CD Welding

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The vast majority of industrial manufacturing processes are highly regulated and standardized in today’s technologically advanced world. The International Organization for Standardization (ISO) and many other regulators have established global guidelines that inform manufacturers, distributors, and customers of the quality of available goods and services. ISO approval registrations aren’t an industry requirement, but without a certificate appropriate to a company’s products, management systems, or practices, trusted customers and partners will be difficult to obtain. Northland Fastening Systems (NFS) follows ISO 9001 certificate regulations for the stud welding industry. As a provider of complete stud welding supplies, we understand the importance of quality parts, tools, and other products as well as standardized services. We offer stud welding supplies for drawn arc, short cycle, and CD welding, including tools for rent or purchase, a full variety of studs, and welding accessories. Our customers also benefit from tool repairs and servicing.

CD Welding

Whatever kind of welding operation you use, there are technical details and specifications that are critical to know and follow. For CD welding, in particular, technical details direct everything from the stud requirements to onsite welding conditions. Some basic CD specifications include:

Studs:

CD studs come in a variety of dimensions that are generally smaller than drawn arc welding studs. CD stud welding utilizes smaller dimension studs, pins, and other fasteners for quick, clean connections that will handle lighter shear loads than drawn arc welds, but meet requirements for food grade equipment, one-sided marking, and rapid operations. Studs come threaded internally or externally, and with partial to full thread specifications. Studs can also be flanged.

Materials:

CD stud welding does not require the use of ceramic ferrules, fluxes, or shielding gas. The weld is completed with an exact calibration of capacitor discharge generated heat and welding gun pressure. Studs are made from mild steel, stainless steel, aluminum, or brass. They can be plated with copper, nickel, zinc, or other materials for various applications. CD studs can also be annealed when required.

Automation:

Because the process doesn’t need to use shielding gas or ferrules and because CD stud welding is a rapid, clean operation that results in a strong weld, it’s ideal for automation. CD studs can be loaded quickly and easily into auto feed systems and equipment controlled robotically through CNC software programs. They can also be loaded into a handheld auto feed gun.

Welding conditions:

CD stud welding requires relatively exact conditions for the successful installation of connectors. The tool, power supply, and other equipment need to be capable of welding the diameter, length, and material of your studs. The weld surface should be clean, free from lubricants or dust, and without imperfections like excessive roughness. The tip size, stud diameter, and angle of the tool must also be applied correctly for a good weld.

To learn more about the CD welding process and our selection of welding supplies, contact NFS at (651) 730-7770 or request a quote online.

Technical Details: Drawn Arc Welding

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Stud welding operations today are highly standardized manufacturing processes. They are widespread across multiple industries as fastening systems, in composite construction, for large-scale construction, food-grade fabrication, and more. If you’re manufacturing in the automotive, building construction, sheet metal fabrication, electronics, food service equipment, fabrication equipment, structural steel, or many other industries, you’ll likely use stud welding systems at some point in the production process. For any drawn arc, capacitor discharge (CD), or short cycle stud welding operations, Northland Fastening Systems has the tools for rent or purchase, studs in a complete range of dimensions, welding accessories, and other supplies welders need to get the job done. For drawn arc welding, NFS provides supplies meeting all technical requirements and weld specifications necessary for a variety of applications.

Drawn Arc Welding

Drawn arc processes are a type of resistance welding, and for stud welding operations, they often utilize ceramic ferrules, fluxes, and shielding gas. From stud specifications to tensile load strengths, some standard drawn arc welding technical details include:

Studs:

Drawn arc studs can be threaded or unthreaded, including various kinds of internal and external threads. Stud lengths are indicated as L in terms of BW (before weld) and AW (after weld). AW lengths will be shorter to various degrees depending on stud dimensions. Dimensions range depending on the type of stud, including threaded connectors, bar anchors, shear connectors, and headed anchors.

Ferrules:

Ceramic ferrules are used to contain molten stud and surface materials at the point of the weld vary in dimensions. The ferrules you pair with your studs should match sizing and meet ISO ferrule standards. A ferrule should be able to be cracked off and removed from the weld point when it has cooled.

Materials:

Drawn arc stud welding materials are generally grades of low carbon steel and stainless-steel meeting AWS and ASTM Some studs are plated in zinc, nickel, or copper. Drawn arc studs can also be annealed to Rockwell B Hardness of 75-85.

Shielding gas and flux:

Semi-inert gases like argon, helium, nitrogen, carbon dioxide, and hydrogen in various compositions protect the weld point from exposure to oxygen and water vapor that can contaminate the weld. Fluxes can also be used to generate carbon dioxide shielding gas and regulate melt temperatures.

Tensile and torque strengths:

Standard arc weld stud tensile load and torque strength ranges are based on stud diameter, threads per inch, mean effective thread area (META), tensile load pounds, tensile stress in pounds per square inch, and torque in inch pounds. In practical applications, studs shouldn’t be installed at their maximum yield load. Instead, a safety range of no more than 60% of a yield strength should be utilized.

Accessories:

In addition to flux, ferrules, and shielding gas, drawn arc accessories include adjustable chucks, cable connectors, headed chucks, ferrule foot plates, and cable lugs.

To learn more about the technical specifications of drawn arc welding for stud installation, contact Northland Fastening Systems today at (651) 730-7770, or request a quote online to get started with us.

Ideal Stud Welding Machine for Low Power Access

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Stud welding operations are used today in many applications, on and off job sites. Because of the range in locales that stud welding is performed, there are a variety of different machines that meet portability, electrical specificity, weld capacity, and material needs. While facilities can house fully automated stud welding systems that churn out hundreds of precise welds per minute, welding technicians in the field rely on their expertise and their specialized tools to get the job done. If you’re working with stud welding in any capacity, Northland Fastening Systems (NFS) offers a complete range of welding tools for rent or purchase, studs for drawn arc, capacitor discharge (CD), and short cycle welding, and welding accessories. While we offer equipment that can be integrated into an automated production line, we also have machines for off-site welding jobs when portability and easy setup is most important. Our HBS VISAR 650, for example, is an excellent stud welding machine for times when technicians only have access to low power electrical sources.

Stud Welding Machine

The VISAR 650 is a small, efficient machine for drawn arc welding with ceramic ferrules. It can handle mild and stainless steel studs. It has a welding current maximum of 650 A and a minimum of 100 A. Because it can perform these welding with only 100-240 V, single-phase power sources, it’s an ideal stud welding machine for working on multiple job sites that have the electrical setups of typical residential and commercial properties. The primary plug of the VISAR 650 is also a standard electrical two-prong grounded safety plug that fits universally into outlets.

VISAR 650

For stud welding on projects in the field, the VISAR 650 has two main benefits for technicians working on different job sites:

  1. The VISAR 650 is simple. It’s a tool that’s easy to learn, quick to set up, and simple to carry from site to site. Its intuitive operation makes it the perfect tool for welders that are trained in many different construction technologies or for welders who only use stud welding processes for specific building requirements. It also has a quick storage system for tidying the tool cable built into the machine handle.
  2. The VISAR 650 is also robust. It has a fully enclosed housing with no air vents, giving it a rating of IP44. An IP44 rating keeps the machine from exposure to solid particulates bigger than 1mm in diameter, and water or other liquids splashing from all directions. This means it has rigorous protection from work site dust, in addition to dirt and inclement weather. The enclosed housing, or casing, is also an effective protection from accidental bumps that frequently occur as tools, building materials, and workers move through an active site. The VISAR 650 has a solid base and side panels that raise the bulk of the machine from the resting surface.

To learn more about our stud welding machine supplies, contact NFS at (651) 730-7770 or request a quote online to get started with us today.

The History and Role of the American Welding Society for Fastening Systems

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While the origin of forge welding can be traced all the way back to the Bronze Age, the history of welding with electrical current only dates back to the early twentieth century. The first resistance welding technology was used extensively in manufacturing military equipment and vehicles for World War I. To establish the importance of the resistance welding industry even after the war ended, former President Wilson appointed Comfort A. Adams, an electrical engineering professor at Harvard College, as chair of the new Welding Committee of the Emergency Fleet Corp. Since then, the committee combined with the National Welding Council to become today’s American Welding Society (AWS). As a provider of stud welding supplies, including tools for rent or purchase, studs in a complete range of dimensions, and welding accessories, Northland Fastening Systems (NFS) follows the standards that the AWS sets for the industry.

High-Quality Stud Welding Equipment

NFS is a comprehensive supplier of high-quality stud welding equipment, and our selection of tools, studs, and accessories, along with our services, meet international standards for operations. In addition to our own standards for quality, original equipment manufacturers (OEMs) and all our other customers follow AWS regulations, and many hold specific AWS certifications.

Since its establishment in 1919, the AWS has been pivotal in advancing and expanding national fastening systems and welding industries in many ways.

A Brief History

After the Welding Committee of the Emergency Fleet Corp and the National Welding Council combined to create the AWS in 1919, the society brought together industry leaders. In its first year of operations, the AWS increased to 217 members and introduced the Journal of the American Welding Society. Although this journal only published one issue, it preceded today’s Welding Journal. The AWS also moved into its new headquarters at the Engineering Societies Building in New York City.

In 1922, the AWS held its first annual meeting, and by then, had established sections in eight major cities. For the next 49 years, the AWS headquartered in New York City, but in 1971, moved to Miami, FL, and then in 2012, moved again to its current location in Doral, FL.

Role of the AWS

In addition to the monthly publication of the Welding Journal, the AWS also offers multiple certification programs, including endorsement certificates, testing facilities accreditation, and fabricator certifications. Certifications include specific programs for welding inspectors, educators, radiographic interpreters, engineers, welders, sales representatives, robotic arc welding, and supervisors.

The AWS also has a membership program and publishes specifications and codes for the industry. Membership is available for individuals, welders, corporations, and students. Currently, the AWS has 250 international sections and student chapters.

As a member of the welding industry, NFS values the history and current global role of the AWS. To learn more about our stud welding equipment, products, and services, contact us by calling (507) 387-7200 or online.

Understanding the Sanitary Properties of Effective Food-Grade Welding

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Using stud-welding operations for fabrication in many industries provides several benefits to manufacturers. Not only is stud welding a quick fastening process that results in a powerful connection point, it also provides clean results without marking the other side of the weld surface or creating rough finishes. Stud welding is useful to many manufacturers working in large-scale construction, heavy-duty composite building, thin pin installation, and even food equipment production. For food equipment, in particular, capacitor discharge (CD) stud welding supports sanitation regulations and hygiene standards for the food production, packaging, and processing industries. If you’re using studs for food-grade welding operations, Northland Fastening Systems (NFS) has the supplies you need. We provide a broad range of tools for rent or purchase, studs in a complete range of dimensions with custom options available, and a full selection of stud welding accessories. Our team of expert welding technicians can also provide advice and information, and our tool repair services eliminate excess production downtime.

 

Via the Food Safety Modernization Act (FSMA), the Food and Drug Administration (FDA) established many guidelines and requirements for every player in the food industry, from farms to food equipment manufacturers. Rules for food-grade welding were also outlined in this act. These rules set specific requirements for finished surfaces, connection points, materials, and all other aspects of manufactured food equipment.

 

Some basic requirements the FSMA sets for stud-welded food service equipment include:

 

  1. Sharps and burrs should be eliminated to prevent microscopic cavities that can house bacteria. When stud welds are performed correctly, there is no risk of micro burrs or sharps around the connection point. Too hot or too cold welds can, respectively, leave molten splatter and burrs, or create a slight ledge underneath the stud.
  2. Materials that are too dissimilar should not be used. While multiple kinds of materials can be welded together in other applications of stud welding, food-grade products should typically be limited to stainless steel or other treated metals that will hold up to corrosion.
  3. Internal corners and angles should be radiused. The FDA requires fabricators to manufacture designs that only use internal angles and corners so that exterior angles are softened and easy to fully sanitize. Sharper angles create crevices for bacteria and other cross-contamination to hide and be difficult to reach even when equipment is fully washed down.
  4. Surfaces should be manufactured without overstressing. When welding is not performed correctly, material surfaces can be overstressed, leading to corrosion, cracking, reduction of protective surfaces, and many other problems that compromise food safety. Accurately applied welds will protect food safety and prevent cross-contamination in the long term.

 

In addition to these requirements, stud welding also makes it possible for manufacturers to support the rule that frameworks should always be sealed and never bolted.

 

To learn more about food-grade welding and our supply of stud welding equipment, contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.

Building Electrical Enclosures with CD Stud Welding

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Electrical enclosures protect delicate circuitry, wiring, and other electronics susceptible to moisture, dust, and many other contaminants. For industries where electrical enclosures need to be installed in areas that are exposed to damaging elements, stud welding is a critical operation that allows manufacturers to build clean, secure systems that eliminate the risk of many contaminants. With stud welding, fabricators can build quickly and efficiently, installing threaded studs, bar anchors, shear connectors, and many other stud formats. Stud connection points are stronger than the stud or surface material, ensuring little risk of a stress failure. If you’re using stud welding in any project, Northland Fastening Systems (NFS) has the tools and supplies you need. We provide a complete selection of tools for rent or purchase, studs in various dimensions, custom stud options, and full welding accessories for drawn arc, short cycle, and CD stud welding.

CD stud welding, in particular, is an important operation for the fabrication of electrical enclosures. Because CD stud welding creates secure, powerful connections with small diameter studs, CD operations are ideal for many types of electrical enclosures. These welding operations also leave no marks on the back of a weld surface, no matter how thin the surface is. This means CD studs can be hidden in the fabrication of clean builds.

Levels of Enclosures

Electrical enclosures meet varying levels of protection, from a simple box installed indoors to rugged casings that keep out heavy contaminants. These levels of protection are based on the National Electrical Manufacturers Association (NEMA) standards.

  1.  First-level enclosures are used indoors to protect people in the vicinity from exposure to hazardous components. These enclosures are simple boxes, such as a household switch box, that encase building circuit switches and keep out a low level of dust and other solid contaminants.
  2. Second-level enclosures can be used either indoors or outdoors to provide protective cases for nearby people; and they keep out low levels of dirt, windblown solid objects, and some degree of water from rain, snow, and ice. These enclosures also protect electronics from ice formation on the exterior of the case.
  3. Third-level enclosures are typically used outdoors to protect nearby people and keep out elements of weather—such as dust, ice on the casing, and corrosion—to a greater degree than second-level boxes. They are not required to be dust-tight or have ventilation systems.
  4. Fourth-level enclosures have the same protective features as third-level casings but to a greater degree, and they are required to be dust- and water-tight. These enclosures can be used in areas where they will be exposed to full water spray for short periods of time, such as in food processing equipment that is washed down and sanitized regularly.
  5. Fifth-level enclosures are fully sealed against water, dust, and other contaminants. They protect nearby people from hazardous parts, and they generally include some form of ventilation system.

CD stud welding is often used in manufacturing all types of electrical enclosures. To learn more about our CD stud welding supplies and more, contact NFS at (651) 730-7770 or request a quote online.

International Standards for Stud Welding Supplies and Operations

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Industrial standards for manufacturing operations, equipment, facilities, worker safety, materials used, and all other aspects of large-scale production work have developed over time since the turn of the 19th century. Today, industrial standards are highly regulated with hundreds of different certifications, licenses, and requirements that manufacturers and processors can meet to exhibit the quality of their products and the reliability of their practices. In the stud welding industry, many resources help companies receive certifications and follow the best standards available internationally. As a comprehensive supplier of stud welding supplies, Northland Fastening Systems (NFS) follows international standards, including the ISO 9001:2015 certification for quality management systems.

ISO 9001:2015

ISO 9001:2015 standards require an industrial facility to demonstrate its ability to consistently offer services and products that meet its customers’ needs and improve customer satisfaction while adhering to applicable regulations and requirements. This is a generic ISO standard, but there are thousands of other ISO certifications, including ones that apply to the welding industry and stud welding supplies.

For stud welding, including drawn arc, capacitor discharge (CD), and short cycle operations, one international standard that gets into specifics is ISO 13918:2017.

ISO 13918:2017

This ISO standard applies to the use of studs and ceramic ferrules in drawn arc welding. It can be used to cover standards for other metalworking industries, but it’s most useful for arc stud welding processes. ISO 13918 covers requirements for using stud types and ferrules, including dimensions, mechanical properties, and materials used.

Details apply to fully-threaded, partially-threaded, and virtually-threaded studs as well as threaded studs with flanges, studs with internal threads, and threaded studs with reduced shafts. Regulations also cover shear connectors and insulation pins.

Ceramic Ferrules

In addition, these standards cover the use of ceramic ferrules that contain molten metal at the connection point. Because ferrules need to be removed easily after the weld is performed, they need to follow strict rules for size, materials, and fabrication process.

ISO standards like 9001 and 13918 provide important guidelines for everyone in the stud welding industry. By following internationally accepted industry standards, companies are able to provide better services and products to their customers; operators can perform safer, long-lasting welds; and parts manufacturers can fabricate tools, studs, and welding accessories in universal formats.

To learn more about our services and full selection of stud welding supplies for drawn arc, CD, and short cycle operations, contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.

Installing Different Types of Insulation with CD Stud Welding

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From residential buildings to skyscrapers, there are varying methods used to construct the skeleton and other foundational components of different building types. Homes and other residential buildings are typically built with lumber skeletons, while skyscrapers and other multi-level commercial buildings require steel beam structures. One common fabrication operation used in virtually almost any building type is stud welding. Stud welding is a versatile construction tool that plays a role in a broad range of building processes. For example, stud welding with shear connectors can allow workers to build composite constructions with concrete and steel. Stud welding can also connect steel beams, create foundations, and much more. If you’re using stud welding in building construction, Northland Fastening Systems has the tools, studs, and accessories you need for drawn arc, short cycle, or CD stud welding.

CD Stud Welding

In any type of building construction, CD stud welding is commonly used to install different types of insulation. Insulation helps conserve energy when heating or cooling indoor spaces, protects areas where fire is a potential issue, lowers interior noise pollution, and more. The following are just a few of the many different types of insulation used today in building construction.

Thermal:

Thermal insulation or weatherizing insulation is the most prevalent type of insulation material used in all types of buildings. These types of insulation are almost always required in residential and commercial buildings in order for them to meet municipal and state construction standards. Industrial buildings may not require thermal insulation, but it’s often in the best interest of a company to include insulation for energy costs, climate-control, and equipment protection. Thermal insulation such as batting and blanket fiber sheets, foam, fiberglass, and more are installed with CD weld pins and other stud insulation fasteners.

Acoustic:

For many indoor spaces, acoustic insulation reduces background noise, exterior noise pollution, and prevents sound travel between rooms. Acoustic insulation is used between apartments, offices, condominiums, and other spaces that are in multi-tenant buildings. Noise insulation is also a key component in buildings used in the entertainment industry, manufacturing industries when sonic diagnostics are necessary, and even in hospital buildings and treatment centers to protect patients. Acoustic insulation sheeting and other formats are installed with CD welding tools and studs.

Fire:

Heat-resistant panels, flame retardant sheeting, and many other types of fire insulation are a necessary installment in most buildings for safety purposes. Fire insulation is used in boiler rooms, electrical hubs, roofing, and many industrial applications. Mineral wool, radiant barriers, ceramic fiber, duct wrap, thermal batting, and other kinds of soft fire insulation are installed with CD pins. Electrical enclosures and other metal sheet flame barriers and fire-resistant panels are built with stud welding as well.

If you’re installing insulation of any kind, NFS can provide the necessary drawn arc, short cycle, or CD stud welding supplies. Contact Northland Fastening Systems today at (651) 730-7770, or request a quote online to learn more.

Renting vs. Owning Stud Welding Equipment

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If you’re working with stud welding operations on your job site or production floor, you can find all the tools, studs, accessories, and expertise you need at Northland Fastening Systems (NFS). Not only do we offer a complete supply of studs for drawn arc, short cycle, and capacitor discharge (CD) welding, and stud welding accessories, but we also work with customers who need custom stud dimensions. Our team of skilled technicians can work with you to determine your exact needs, including the purchase or rental of stud welding equipment and tools.

NFS supplies stud welding tools that fit a variety of operator needs. We have available, for rent or purchase, portable, lightweight welders that are ideal for moving to different locations on a job site; heavy-duty handheld welding guns for installing shear connectors in a composite build; fully automated systems that can be integrated easily into existing facilities; and everything else in between.

Stud Welding Equipment

There are benefits to both renting and owning stud welding equipment, depending on your priorities and situation. If you’re looking to get started in stud welding but aren’t sure whether renting or owning equipment is a better fit, consider the following benefits of each.

Renting Benefits

  • By renting stud welding equipment, you avoid the majority of maintenance and repair expenses.
  • You can also avoid downtime if unexpected and expensive repairs are needed.
  • Rented tools are easier access and cheaper options for short-term projects or one-time jobs.
  • You can pick and choose from a variety of newest and specialty models.
  • You don’t have to commit to one tool that might be perfect for one job and slightly imperfect for another.
  • Extra studs, accessories, ferrules, and other components are supplied with rental tools in case one breaks.
  • You can become a more versatile welder if you have the opportunity to work with multiple brands, welder types, and processes by renting tools.

Owning Benefits

  • By owning a stud welding equipment, you can perform your own maintenance, so you’ll always know what to expect.
  • Tools are conveniently at hand.
  • For long-term jobs or if you are a stud welder by trade, owning your own tools is by far the cheaper option than renting.
  • You get to know your tool very well and can improve your precision with practice.
  • You learn how to repair your own tool.
  • Owning your own tools improves your professional image.
  • The better you learn your tool, the faster you can work, which saves you money, time, and physical fatigue.

When you get your tools from NFS, you’ll get the continued support, repair service, and advice of our technicians no matter whether you rented or purchased equipment. To learn more about our supply of stud welding equipment, contact NFS at (651) 730-7770. Request a quote online to get started with us today.