Author: norfas

Integrating an Automated Stud Welding Process

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

 

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

 

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

 

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

 

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

 

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

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

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

 

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

 

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

 

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

 

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

 

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

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

 

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

 

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

 

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

 

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

 

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

 

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

NFS Welding Studs 101

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Since 1987, Northland Fastening Systems (NFS) has supplied the stud welding industry with quality tools, welding studs, accessories, and our own expert advice. Our supply of welding studs and accessories covers a comprehensive range of dimensions, materials, and additional specifications. Welders working with drawn arc, capacitor discharge (CD), or short cycle welding can find the welding studs they need with NFS, including any specifications from threaded studs used in an automated system to CD pins hand-installed in the field to shear connectors used in composite construction. As a specialty welding operation, manufacturers using stud welding take advantage of its speed and ability to form a connection stronger than the stud itself. When done correctly, stud welding is a highly clean and efficient operation that poses little physical danger to the welder. You can incorporate the benefits of stud welding onto your production floor with the help of NFS technicians, our tools—for rent or purchase—and our complete collection of welding studs and accessories.

 

The most common types of stud welding include drawn arc and CD. Studs suitable for each welding operation will vary, and depending on what your surface material, fastening system specifications, and dimension requirements are, the welding studs will vary within each category. All of the following studs are available in multiple diameters and lengths, and we offer custom stud-sizing options.

 

Drawn Arc Studs

Typically speaking, drawn arc welding studs are slightly more heavy-duty than CD welding studs. They fit in larger dimensions; are made from mild, low carbon, or stainless steel; and take longer to weld. NFS offers fully threaded or partially threaded arc welding studs, headed anchor welding studs for concrete connections, shear connectors for composite constructions, and deformed bar anchors for weld and bearing plates.

 

CD Studs and Pins 

CD stud welding is used as a rapid, lightweight, clean fastening operation for smaller studs and CD pins. We offer flanged and threaded CD studs in standard and small sizing and non-flanged and threaded studs in standard sizing. NFS CD studs are fabricated with aluminum, mild steel, stainless steel, or brass. Mild steel CD insulator pins are also available in standard sizing.

 

Accessories

For both drawn arc and CD welding, we have a range of accessories that are necessary to make adjustments to tools, work with ferrules, and more. We offer a variety of cable connectors, ferrule plates, split feet, closed feet, chucks, spark shields, collets inserts, tube adapters, B stops, and more.

 

Whether you’re working with drawn arc, CD, or short cycle welding operations, our goal is to provide you with all the stud welding supplies you need to help your job go smoothly. To learn more about our available welding studs and all our other welding supplies, contact Northland Fastening Systems at (651) 730-7770. You can also request a quote online to get started with us today.

Resistance-Welded vs. Arc-Welded Fastening Systems

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At Northland Fastening Systems, we provide a comprehensive supply of stud welding supplies, from tools for rent or purchase to studs in a complete range of dimensions with custom sizes available. Whether you need tools, studs, and accessories for drawn arc, CD, or short cycle stud welding, NFS has the products and the expertise of our stud welding technicians to help you get the job done.

 

In the industrial world, types of stud welding are typically grouped into a manufacturing category different from other welding operations. Other common welding types, such as resistance welding, can be used as fastening systems, but stud welding is generally considered the most effective method for installing fasteners and studs. Due to its unique ability to generate a connection point stronger than the fastener itself, stud welding is usually chosen over other fastening systems when manufacturing assemblies of any size that require studs, bars, anchors, and other fasteners.

 

While stud welding is the primary choice for fastening systems on the production floor or jobsite, resistance welding can sometimes have its uses when installing various fasteners.

 

Arc-Welded Fasteners

Stud welding connection points are created using an electrical arc generating enough heat at the base of the stud/fastener to put both stud tip and surface material into a molten state. In the stud welding process, the arc creates a true fusion of the two metals. Stud welding types include drawn arc, capacitor discharge, and short cycle. Arc-welded fasteners can be installed without leaving marks on the opposite side of the base material. They can also be rapidly installed, with some automated machines performing up to 60 welds per minute. Drawn arc welding can be done on angled or curved surfaces, and CD welding can be used to install fasteners on surfaces as thin as 0.016” for steel and 0.04” for aluminum without causing warping or discoloration. Stud welded fasteners are also leak-proof and pressure-tight.

 

Resistance-Welded Fasteners

Resistance welding includes spot and projection welding. These processes are used to install permanent fasteners with internal or external threading. To achieve an effective weld, both fastener and surface must be fit for resistance welding, which lessens the range of scenarios where resistance welding would be useful as fastening systems. Parts, equipment, and transportation costs of using resistance welding for fasteners are typically much higher than those of stud welding, so the recommended production volume to justify costs is over 1,000.

 

Overall, using arc/stud welding is lower cost, faster, and more effective than resistance welding for installing fasteners. To learn more about fastening systems and our stud welding supplies and services, contact Northland Fastening Systems at (651) 730-7770. Request a quote online to get started with us today.

Quality Stud Welder Highlight: MFI Sureshot for CD Stud Welding

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Northland Fastening Systems is a global provider of high-quality stud welding supplies including stud welding tools for rent or purchase, a comprehensive range of welding studs, welding accessories, and the expertise of our own stud welding technicians.

 

In addition to a broad range of threaded and non-threaded studs for drawn arc and CD stud welding, insulation fasteners, CD pins, bar anchors, shear connectors, and anchor studs available in multiple materials and dimensions, we also have options for custom stud specifications. Our selection of tools available for rent or purchase also has a broad range of options. For those on a permanent production floor, we have multiple fully-automated fastening systems, but we also have lightweight, portable tools for welders in the field, as well as everything in between. This welding tool highlight covers a popular unit for rapid CD stud welding with relatively smaller studs that form powerful connections with a welding surface.

 

Thanks to its compact carrying case and weighing a total of only 18 lbs., the MFI Sureshot is ideal for welders working on a jobsite where multiple locations require welding operations. Easily portable, the MFI Sureshot allows welders to perform quick CD stud welding operations that are clean with little spatter and no marks on the opposite side of the weld surface.

 

MFI Sureshot Specifications

 

  1. Electrical: The MFI Sureshot operates with 110/220 VAC, 15/7.5 Amp, and 50/60Hz incoming and 35-160 VDC, 3,000-9,000 A, and direct current outgoing, with 100,000 uF capacitance.
  2. Welding range: This CD stud welding unit has a pin and stud range of 14 gauge through a 5/16” diameter at the weld base. The welding operation is effective with mild and stainless steels as well as aluminum. It operates quickly for a small unit with 24 welds per minute in the highest voltage. Each charge between welds is less than 3 seconds.
  3. Operation details: The MFI Sureshot unit features three indicator lights and a resettable breaker with additional safety shutdowns. The system is continually cooled with a thermal fan, and the 7-segment digital display offers welders direct control with ease.
  4. Welding gun: The welding gun weighs only 1.6 lbs. for long-term use without exhaustion. The gun is made from high strength, impact resistance polycarbonate. Gun dimensions are 4 ⅞” L x 2” W x 5 ¾” H.
  5. Cables: The MFI Sureshot comes with a standard set of #4 grounding cables and gun cables. The grounding cable reaches up to 15 ft and the weld cables reach up to 20 ft from the gun, allowing welders a broad range of motion around obstacles in the field.

 

The MFI Sureshot is one of many welding tools we have in our collection. To find out more about this CD stud welding tool and many others, contact Northland Fastening Systems at (651) 730-7770. Request a quote online to get started with us today.

International Standards for the Stud Welding Process

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All manufacturing industries follow a set of international standards outlined through the International Organization for Standardization (ISO) in addition to various requirements and certifications unique within any given industry. Overall, there are more than 18,500 ISO standards and around 1,000 new published annually. Despite the vast number of ISO certifications, some industries are relatively specific enough to only require a few ISOs to follow the continually updated editions.

 

When it comes to stud welding, ISO 13918 standards cover the majority of common arc procedures including drawn arc, CD, and short cycle stud welding. For all these types of the stud welding process, Northland Fastening Systems provides a comprehensive range of supplies meeting ISO 13918 standards. Our supplies for the stud welding process include welding studs in various dimensions with custom options available, welding tools for rent or purchase, stud welding accessories, and the expertise of our own staff of stud welding technicians.

 

One current standard for the stud welding industry is ISO 13918:2017. In addition to stud welding, this ISO can be generally applied in most metal working fields, but those working with the stud welding process will find the specifics most useful to their production floor.

 

ISO 13918:2008 covers requirements for arc welding studs, dimensions, materials, and mechanics, including:

 

  • unthreaded studs
  • partially-threaded studs
  • fully-threaded studs
  • virtually fully-threaded studs
  • flanged and threaded studs
  • threaded and reduced shaft studs
  • internally-threaded studs
  • insulation fasteners
  • shear connectors
  • welding pins
  • the use of ceramic ferrules

 

The standards and mechanical guidelines that ISO 13918 provides offer in-depth information that not only helps welders improve the stud welding process and fabricate better quality products, but also helps manufacturers better understand the application of stud welding in their own industries and play a role in supporting the continued growth of universal standards.

 

As a supplier for hardware and tools used in a range of stud welding processes, we follow our own set of ISO standards at Northland Fastening Systems. We are ISO 9001:2015 certified as an industrial supplier. While ISO 9001 is a relatively generic set of standards, following those requirements helps us maintain best practices and support our customers with quality products and advice. By following ISO 9001 standards, we continue to show our capabilities in providing the stud welding industry with necessary products that meet regulations, and we work as a customer-focused company that aims to improve consumer satisfaction while adhering to internationally-accepted requirements. NFS uses the regulations that ISO 9001 provides as a quality management system to continue offering our customers the best products and services for drawn arc, CD, and short cycle welding.

 

To learn more about the products we provide for the stud welding process and ISO certifications, contact Northland Fastening Systems at (651) 730-7770. Request a quote online to get started with us today.

Selecting the Right Steel for the Insulation Fastener Stud Welding Process

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Stud welding is used so prolifically across widely different industries that it often pops up in unexpected applications. Not only is stud welding used extensively in the automotive and construction industries, it’s also effective in building food-grade equipment, electrical enclosures, and even insulation and roofing. No matter how you are utilizing stud welding, you can find the supplies you need at Northland Fastening Systems (NFS). We provide a comprehensive range of welding studs for drawn arc, CD, and short cycle welding with additional options for custom dimensions. NFS also offers welding tools for rent or purchase and stud welding accessories. Our team of expert technicians has the training and skills to help you get whatever tools you need to complete your stud welding process.

 

Stud welding is a key operation for composite construction, including in building insulation and roofing. When it comes to welding insulation fasteners and roofing components, it’s important to select the right type of stainless steel for the stud welding process you’re working with.

 

All materials used in welding insulation fasteners must meet the standard guidelines of the American National Standards Institute (ANSI) and the American Welding Society (AWS). Within these standards, stainless steel grades typically approved are 300s in non-magnetic states with basic annealing. This includes 302, 304, 305, 309, 310, and 316. While 304 (also listed as 18/8) and 305 are the most commonly used in typical insulation fastening and roofing component welding, other stainless steel grades in the 300s are beneficial in their own way for certain applications.

 

Steels in the L series, like 316L, are often the most effective choices when resistance to corrosion is critical. In high heat applications, SS series like 320SS and 330SS are most effective, but for extreme temperatures and refractory applications, super alloys like Inconel 601 are more effective than stainless steels. Stainless steel temperature ranges for the insulation fastener stud welding process vary between 1,400ºF and 2,000ºF, while Inconel is used in applications around 2,200ºF. Steel grades 302, 304, and 305 are best at 1,400ºF applications, and 316 is best at 1,700ºF, 310 is best at 1,850ºF, and 330 is best at 2,000ºF.

 

No matter what insulation fastener and roof component stud welding process you’re utilizing, choosing the right stainless steel or other material is a requirement. Plan ahead your production schedule with attainability and lead time of acquiring different steels in mind. While many steel types are easy to source, some need to be special ordered with longer lead times.

 

To learn more about choosing the right type of metals for your specific stud welding process and the products we have available, contact Northland Fastening Systems at (651) 730-7770. You can request a quote online to get started with us today.

Spot Welding vs. The Stud Welding Process

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Welding is one of the older manufacturing operations still used extensively throughout industries today, with the first types of forge welding dating back to the Bronze and Iron Ages in the Middle East and Europe. Today’s modern welding techniques vary greatly in their processes and results. Stud welding, for example, is a much different process than resistance welding, but each type of welding has its place in the manufacturing world.

 

When it comes to stud welding, industries from shipbuilding to food-grade equipment fabrication all value its benefits and capabilities. Not only does stud welding create a connection point stronger that the stud itself, it’s also a rapid fastening system with clean results.

 

No matter what industry you work in, you can count on Northland Fastening Systems to provide a complete supply of tools, studs, accessories, and everything else you might need for the stud welding process.

 

While stud welding is sometimes confused for spot welding, they are two very different operations. Spot welding actually falls into the category of resistance welding or resistance spot welding (RSW), whereas stud welding is an arc welding operation.

 

Spot Welding

Resistance spot welding uses heat to join metals together. That heat is generated by resistance to electrical current. The heat brings the two pieces of metal being joined together to a range where they can be connected with high-pressure systems. The metals technically never melt to a molten state during a spot-welding process. Because of this, spot welding is more like a forging process. The metals do not intermix in the same way they do during a stud welding operation. Spot welding has limited uses because it works well with few materials. Primarily, spot welding is used with low-carbon steel, but it can be used to form brittle connections with high-carbon steel and aluminum alloys.

 

Stud Welding

Stud welding uses a drawn arc or capacitor discharge (CD) arc to generate heat at the connection point. The metals used are heated to a molten state and the metal molecules fuse together to form a strong connection. Whether you’re working with drawn arc, CD, or short cycle stud welding, the high heat involved can be used to weld on a much broader range of surfaces than spot welding. Stud welding also doesn’t require the high-pressure equipment that spot welding does and can be used even when access to the reverse side of the base material cannot be accessed.

 

Overall, the stud welding process is a more flexible, efficient, and powerful choice for many production floors. To learn more about the capabilities of stud welding, contact Northland Fastening Systems at (651) 730-7770, or request a quote online to get started with us today.

Buyer’s Guide to Choosing the Right Welding Equipment

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Whether you’re an experienced stud welder or just getting into the different types of stud welding that are each highly useful in its own way, selecting the right welding equipment can be difficult. Each welding unit and welding gun has its own set of exacting specifications, including power requirements, calibration ranges, material requirements, and much more. At Northland Fastening Systems (NFS), we offer a comprehensive range of stud welding equipment and other stud welding supplies, including tools for rent and purchase, studs in a broad range of dimensions, custom stud options available, and stud welding accessories. In addition to our extensive collection of stud welding supplies, our welding technicians offer their own expertise in the industry. Our team of knowledgeable stud welding technicians work with customers to help them select the right welding equipment so they can get the job done efficiently.

 

Choosing the right stud welding equipment can be difficult because there are many factors to take into account. The most important considerations before choosing a stud welding unit or gun include the following:

 

  1. Power source: Knowing your power source before selecting any welding equipment is key. Not only is it important to know whether your power source will be capable of providing enough welding power, some stud welding equipment requires a transformer or inverter, while others will need a capacitor discharge source.

 

  1. Arc generation: Drawn arc, capacitor discharge, and short cycle welding all use a different type of arc. Because of this, you need to understand how your welding arc will be generated and determine if your energy source will be capable of providing the necessary direct current.

 

  1. Weld time: For any production job, one goal is to limit downtime and work with the greatest efficiency possible. Many stud welders will use rapid welding operations to their advantage and build a schedule around how many welds per minute are possible. Not only do welds per minute vary between types of stud welding operations, they also vary between machines. Knowing the weld times you’ll need to meet production schedule requirements is a significant factor that will guide your selection.

 

  1. Weld abilities: Finally, one of the most important factors to consider when choosing welding equipment is what abilities that equipment has. Do you need a tool to perform CD welding or drawn arc welding? Are you working with steel or aluminum? What kind of surfaces are you welding on? What size studs will you be working with? All of these questions determine the capabilities of your welding equipment and should guide your decision when selecting which tool to work with.

 

To learn more about welding equipment specifications and which tool is right for you, contact Northland Fastening Systems at (651) 730-7770 or request a quote online today.