Author: norfas

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.

Building with Structural Steel Welding and Sheet Metal

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When you look around your world, it’s highly likely your eyes will fall on something manufactured with stud welding. Whether it was built relying on the composite construction of shear connectors, steel, and concrete (such as bridges and roads), or with threaded fasteners or food-grade welding (such as automobiles and kitchen appliances). There are thousands of applications of stud welding that build the objects, structures, and tools we interact with on a daily basis. For any type of stud welding operation, including drawn arc, capacitor discharge (CD), and short cycle, Northland Fastening Systems (NFS) supplies a comprehensive selection of welding tools for rent or purchase, studs in varying dimensions, custom stud options, and welding accessories. If you’re working with sheet metal or fabricating with structural steel welding, we have the supplies you need to get the job done.

Structural Steel Welding

The structural steel welding and sheet metal industries are just some of the many sectors NFS provides with a complete range of supplies. Both structural steel and sheet metal are important materials in their own ways, but they are often used in very different applications.

Composite Construction:

Structural steel, such as beams, girders, columns, tubes, and other extruded parts, are more commonly used in composite constructions. Structural steel has a high load-bearing capacity, relatively high thermal resistance, tensile strength, and corrosion resistance. This makes structural steel ideal for heavy-duty manufacturing. In fact, most multistory buildings, like skyscrapers, rely on structural steel for their height. When combined with stud welded shear connectors, structural steel can also be attached to concrete slabs. This composite type of construction and other composite builds using studs or shear connectors is used in building bridges, roads, high-rise building floors, airport runways, and much more. With shear connector studs, steel and concrete composites have proven to be one of the safest and longest lasting applications for large-scale structures.

Cosmetic Construction:

Sheet metal, on the other hand, is more commonly used to create sleek, cosmetically desirable finishes. While sheet metals are used in structural fabrication in many instances, it’s often thinner, more flexible, and less suited to heavy-duty building. However, because studs can be welded onto even very thin sheet metal without leaving a mark on the opposite side of the weld surface, it’s ideal for creating clean designs that are attached with strong connection points. Sheet metal stud welding is used cosmetically in many applications, such as building exteriors, vehicles, appliances, electrical enclosures, ships, water towers, and more.

In both of its respective applications, with structural steel and sheet metal, stud welding will save time and money while also performing extremely strong and durable fastening systems.

To learn more about sheet metal and structural steel welding contact, NFS at (651) 730-7770. You can also request a quote online to get started with us today.

 

Automated Production Stud Welding Machine Rundown

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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

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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

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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.