Author: norfas

The stud welding process is a widely used group of operations in the manufacturing world. Because the process has so many applications, manufacturers find it highly advantageous to be able to automate stud welding on a production line. Streamlining stud welding into an automated production line process allows manufacturers to increase speed, precision, quality, and efficiency for any fabrication project. If you are working with stud welding as a contract manufacturer or professional welder, you can greatly increase your output without compromising quality by implementing production line practices in your facility. At Northland Fastening Systems (NFS), we provide a broad range of tools to automate your stud welding process as well as tools, studs, accessories, and expert services to support your current non-automated stud welding operations.

Whether or not you have the facility accommodations to integrate a fully automated stud welding process, you can always implement elements of a production line in certain ways. Handheld stud guns and other units can be effectively used in a production line setting, although the most efficient process in many cases is automated.

Non-Automated Production Line

The general structure of a production line is designed to operate in stages, with each step of the fabrication process occurring at its own stage. When it comes to non-automated stud welding, forming a production line is entirely possible. An example of an effective non-automated production line process might include these steps:

1. The surface of the base material is cleaned or otherwise prepped.
2. Any shielding gas that will be used in a drawn arc process is prepped.
3. The gun tip is prepped, including any ferrules, fluxes, and stud that might be used, depending on the weld type and the necessary stud dimensions and material.
4. The weld is performed.
5. Ferrules and other waste materials are removed.
6. The weld is inspected for quality.

In this scenario, the majority of the process will be performed by a welding technician, and likely one weld will be performed at a time. When it comes to automation, there are a few key differences that make a production line more efficient.

Automated Production Line

Automated stud welding processes are typically used in sheet metal construction where a large base material can be fed through a conveyor system, but there are some other applications that can feed smaller components that are not necessarily in sheet form through an automated system. Automated production lines often use stud welding tools controlled by a software system. Each step of the process can be done in bulk, including the performance of the weld with multiple stud welding tips. In some facilities, up to 40 studs can be welded in one step, and the software used in a welding process can be calibrated to highly specific results. This can include intricate patterning of the studs with precise placement.

To learn more about integrating an automated or non-automated production line stud welding process into your facilities, contact Northland Fastening Systems at (651) 730-7770 or request a quote online today.

Like any other aspect of the commercial manufacturing industry, stud welding has its own set of regulations. Stud welding practices, tools, and materials are all regulated in certain ways to U.S. and worldwide standards. In addition to the regulations specific to stud welding, there are universal standards for all types of welding, including electrical specifications according to the National Fire Protection Association (NFPA) and the National Electrical Code (NFPA 70) the NFPA outlines.

If you’re working with stud welding tools, understanding the regulations of the NFPA and general electrical standards can be a key part of the job. At Northland Fastening Systems, our expert technicians can provide guidance, and our primary role as a stud welding supply shop offers a comprehensive range of tools for rent or purchase, studs in many dimensions, and stud welding accessories.

In the U.S., the NFPA covers a broad range of regulations for electrical situations depending on the location, purpose, and general circumstances. When it comes to electrical safety in the workplace, especially in terms of a manufacturing setting, the NFPA 70E regulations detail the exact specifications facilities need to meet.

The goal of the NFPA 70E standards is to “provide a working area for employees that is safe from unacceptable risk associated with the use of electricity in the workplace.” To reach this goal, a broad range of workplace specifications must be met, but generally speaking, it addresses the following:

• Electrical conductors and electronic equipment installed inside buildings and other structures or installed on those structures
• Conductors that connect those installations to a power source

While the NFPA 70E also covers numerical specifications concerning voltage, hertz, heat, conductivity, calories/cm2, and other properties of electrical systems, it also includes more general regulations for the workplace. For example, designating a safe work zone with proper signage, warnings, and distancing precautions is a significant part of any stud welding site. Setting standards that take into account sparking, shielding gas, and personal protective equipment are also key to the NFPA 70E.

Overall, most stud welding technicians have a strong grasp on safety measures, and many welding units take into account electrical issues like surges. If you’re working with any NFS tools and equipment, you’re using high-quality stud welding products that will not have any electrical problems when used properly. NFS provides state-of-the-art tools through our rent or buy options, our studs can be custom made to fit your exact specifications, and all our experts are just a phone call away.

To get started with Northland Fastening Systems on your project today, contact us at (651) 730-7770 or request a quote online.

When performed correctly, stud welding applications can provide a fastening system with connection points stronger than either the welding stud or the base material. The basic result of a stud weld is a chemical combination of the two metals being connected, rather than just an adhesion. This chemical bond between two different components is a critical tool for a wide range of manufacturing industries. If you rely on the stud welding process for your production operations, you can find everything you need at Northland Fastening Systems to get your job done efficiently and effectively. From studs in a comprehensive range of dimensions to welding tools for rent and purchase, our expert technicians and knowledgeable staff can help you get all the accessories you need.

Whether you are using drawn arc or CD (capacitor discharge) techniques, each stud welding process has similar stages and requires the same level of inspection processes. Weld inspection is a critical aspect of a well-executed welding operation. For all stud welding processes, the following basic components comprise a thorough weld inspection.

1. Spattering: One sign of an obvious issue in a weld is spattering, which is splashed or spattered molten metal around the weld point, that points to a too-hot weld. Overly hot welds cause weaker connections and shorten the stud length more than desirable.

2. Burn through: Another sign of a too-hot weld is burn through of the stud too deeply into the base material. This issue leads to rapid metal fatigue and a poor visual result.

3. Dull/low flashing: A cold weld, on the other hand, shows slightly different, but easily identified issues. First, a cold weld problem results in dull flashing or a low level of molten metal around the weld point. Cold welds can also result in a failed connection or damaged stud.

4. Stringing: Another clear sign of a cold weld problem is metal stringing around the weld point. This slight spattering has longer, duller strands of molten metal around the connection than hot weld spattering.

5. Undercut: If poorly centered, improperly aligned, or welded with too much lift, a weld can show an undercut at the connection point. This means the weld was “hung up” and has a weak connection. Other issues of an undercut is little flashing and a long stud length.

6. Bend: The bend test is one last test after initial inspections that can reveal welding problems. In stressing a stud and connection point by bending it back and forth, you can ensure your welding tools are correctly calibrated. If the weld connection point breaks before the stud, your tools are not performing correctly. In any good stud weld, the stud should snap before the connection point cracks or breaks.

With these simple visual inspections and the bend test, you can eliminate the majority of weld issues. To learn more about the stud welding process and troubleshooting a weld, contact Northland Fastening Systems at (651) 730-7770. You can also request a quote online to get started with us today.

Stud welding is typically associated with the fastening together of two steel bodies. While this is often the case, welding can also be used with a variety of metals and other nonmetal materials such as plastics. One of the secondary metals used in welding processes is aluminum. In fact, when it comes to welding studs on an aluminum surface material, the right process can create a strong weld that is effective in the long term. If you are working with aluminum in your stud welding process, Northland Fastening Systems (NFS) provides the tools, studs, and expertise you need to get the job done effectively and efficiently.

Welding studs on an aluminum surface can be a more difficult task than working with steel materials, largely because aluminum is a much more conductive metal, both thermally and electrically. A higher conductivity at the weld point draws heat away from the stud, rendering the temperature insufficient to form a strong connection. Without correctly preparing the weld process, welding to aluminum surfaces can be like trying to heat up a cup of coffee during a blizzard.

The best way to achieve a strong stud connection to aluminum is to prepare the surface and correctly calibrate the stud welding process.

• Surface Preparation: Aluminum surfaces can easily build up oxides. For a quality weld, these oxides need to be removed with a stainless steel brush. After brushing off oxides, surfaces should be wiped down with a non-VOC cleaner.
• Weld Speed: Both CD and drawn arc stud welding processes should be done as quickly as possible when working with aluminum. Speed can help limit the unwanted conduction of heat away from the weld. CD weld times, for example, are completed in 10 milliseconds.
• Shielding Gas: If you are using drawn arc stud welding with aluminum, then shielding gas is a requirement. This gas is critical in generating enough heat at the weld point and combating aluminum’s higher conductivity. Most welders use 100% argon shielding gas, but 100% helium or a mixture of helium and argon are also useful in aluminum welding.
• Ceramic Ferrule: Like shielding gas, ceramic ferrules are necessary when drawn arc welding onto an aluminum surface. This ceramic ferrule contains the tip of the welding stud, and more effectively distributes heat and shielding gas around the weld point.
• Stud Design: Another key difference in aluminum welding is the stud design for drawn arc stud welding processes. The best aluminum studs have a built in ignition tip that burns away before the weld is performed. This allows the welding arc to last longer and generate more heat than a typical welding stud would.

To troubleshoot an aluminum stud weld result, examine the connection point and surrounding surface material. If there is a flash ring or if the stud and/or surface are left shiny, the weld was not performed correctly.

Learn More About the Stud Welding Process

To learn more about the stud welding process when working with aluminum, contact Northland Fastening Systems at (651) 730-7770. Request a quote online to get started with us today.

The industrial world today is broad with many differences between facilities, equipment, practices, and products between manufacturing types. Despite this, there are some natural similarities between each production floor. One of the most important commonalities between every industry is the need for continued maintenance. Whether that maintenance is reactive due to a break, preventative with routine schedules, or predictive depending on diagnostic information, it’s a critical component of any effective production practices.

At Northland Fastening Systems, our service technicians provide maintenance guidance to our customers who are utilizing stud welding equipment as their primary fastening systems. In addition to knowledge, the comprehensive supply of studs, welding tools, and accessories we offer are a key part of an effective maintenance program.

Compared to many other industrial applications, stud weld fastening systems are relatively simple tools, and maintenance is often easily performed even by beginning welders. However, that doesn’t mean that it’s not important. For reliable performance results, your stud welding tools need effective maintenance care.

There are three main components in stud welding systems that require regular maintenance or replacement of parts depending on age and condition:

• Stud gun: Stud welding guns are the most important components to generating a strong weld connection. The stud gun tip holds the stud in place and provides a connection to the surface for the arc to generate enough heat for a weld. Without maintenance, buildup and heat damage to the mechanics of the gun can cause weakened or messy welds. It’s typically recommended that technicians using a stud gun 500,000 times per year or more should clean and inspect the gun condition four times annually. Any use less than 250,000 yearly should perform maintenance twice annually.
• Cabling: The four main cabling components of a stud weld system carry power from the source to the gun. This includes the incoming power cable, the weld cable carrying power to the welding gun, the ground cable carrying the current back to the power source, and the control cable that triggers and lifts power signals from the source. These cables need visual inspections to determine their safety and reliability. Damaged cabling or insulation can be fatal without regular maintenance.
• Power source: Because welding is an electromechanical process, power source controls are necessary components to maintain. This primarily includes knobs, switches, fans, and contactors. While these don’t need rigorous maintenance, they can be damaged over time due to dirt buildup or heat exposure. This is often the case for systems continually using cooling fans that draw in a higher level of dust. Routine checkups will easily prevent any issues.

With minimal maintenance, most stud weld fastening systems have an effective lifespan of 20 years or more. If you’re using stud welding tools and need supplies or technical support, NFS has all the components, accessories, and knowledge you need to get the job done. Contact us at (651) 730-7770 or request a quote online to learn more about our fastening systems today.

All across the U.S., more and more states are initiating a statewide lockdown due to the spread of the coronavirus outbreak. These shutdowns are limiting public operations to essential personnel like medical professionals, food suppliers, pharmacies, and gas stations.

The fact that construction workers and construction companies are considered to be essential operators during this time has been in some debate. While some construction operations such as interior decoration, unnecessary remodeling, and other cosmetic building are not exactly essential, there are many reasons why critical construction projects should continue during a lockdown.

If you are working on an essential project that integrates stud welding into the operations, you can count on Northland Fastening Systems for all your supply needs. We offer everything necessary to any stud welding project including tools for rent or purchase, studs in a wide range of dimensions, accessories, and technical support services.

There are many reasons why construction could be considered an essential service during times of crisis. The stud welding operations our customers use to build goes into the production of many much-needed structures, tools, components, and full assemblies. Some of what is constructed during this time might be what saves hundreds of lives. It may be a product that increases patients’ comfort, provides shelter for those in need, or plays a role in getting quarantined communities the supplies they need.

There are many other circumstances when stud welding and other construction operations are essential. Even during a lockdown, state governments recognize that construction services must still be available. To learn more about what we can do to help as a stud welding provider, contact Northland Fastening Systems at (651) 730-7770, or request a quote online to get started with us today.