Author: norfas

Contact versus Gap CD Stud Welding

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Stud welding is a manufacturing operation that is highly saturated in use across industries. Not only does stud welding provide fast, strong fastening systems, but it also creates clean, consistent connection points for a variety of stud and surface materials. You can find everything you need regarding tools, studs, pins, and other welding accessories at Northland Fastening Systems (NFS). In addition to a comprehensive selection of products, NFS also offers expert guidance via the knowledge of our skilled stud-welding technicians. From drawn arc to capacitor stud (CD) stud welding, NFS has the supplies and service that production teams of any size need to get their projects completed quickly and effectively.

 

Drawn arc stud welding is an excellent option for large-scale welding of heavy-duty studs on a variety of steels and other metals, but CD stud welding may be an even better option for welders working quickly with smaller dimension studs on surfaces that need to look clean.

 

CD stud welding uses a quick-draw welding tool that is either a handheld gun or an automated production tip. There are two types that can be used, depending on the materials being welded together and the production speed needed.

 

  • Contact CD Stud Welding: This is a slightly more common type of CD stud welding that physically presses the stud against the surface material while an electrical current heats the two metals. A stud is inserted on the tip of the welding tool and positioned against the flat base surface. This allows the electrical current to flow through the welding tool to the surface material, heating and rendering molten metal beneath the stud. The current also vaporizes the tip of the stud, allowing it to stick to the molten surface and cool to form a strong fastened connection. This process typically occurs in just 0.012 seconds. Contact welding is ideal for steels and other metals that have a slightly higher melting point than others.
  • Gap CD Stud Welding: Gap CD Stud Welding involves a different gun and the use of a magnetic coil, or solenoid, that activates and lifts the stud away from the workpiece. It still draws an arc and plunges back into the weld pool under significantly less spring pressure than contact stud welding. This is beneficial for aluminum and stainless steel where it’s critical to not leave a mark on the backside of the workpiece. We often see this with sign manufacturers who want a clean appearance.

 

Whether you are using contact or gap CD stud welding as a primary fastening system at your worksite, NFS has what you need to get the job done. Contact Northland Fastening Systems at (651) 730-7770 to learn more about stud welding supplies. Request a quote online to get started with us today.

Time, Pressure, Current, and Other Specifications for CD Stud Welding

Posted on by norfas by norfas

There are several types of stud welding used in a wide range of manufacturing procedures. The use of CD stud welding as a fast, clean, and strong fastening system is a highly effective technique for rapid fastening of a broad variety of structures from lightweight assemblies to composite material construction.

 

If you’re using CD stud welding as a primary fastening system for any size project, you can find studs in a wide variety of dimensions, including custom sizes, stud welding tools for rent or purchase, all the accessories you might need, and our own stud welding technicians’ expertise at Northland Fastening Systems today.

 

Utilizing CD stud welding as a primary fastening system for your construction procedures can be one of the most efficient methods at hand if used correctly. While CD stud welding is a quick, easy way to form strong connections, it also requires specific calibrations depending on the tool, stud dimensions, and materials used. CD welding processes change effectiveness whenever specifications are altered. These specifications include:

 

  • Time of weld: The speed of a CD weld can affect the strength of the weld. If a weld is performed too quickly, it can create a weak connection. If a weld is too long, however, it can produce a weakened connection point with too deep of a penetration and unattractive spattering of molten stud and surface material.
  • Pressure of weld: CD stud welding requires a very specific pressure through the welding gun to provide a perfect connection with a strength greater than stud and surface material alike. Too great a pressure calibration creates a spattering and too deep penetration. Too little pressure provides a weak connection that is not fully formed.
  • Current/power of tool: Just like the time and pressure, a specific electrical current is required to perform a strong weld connection. The current required depends on the materials being welded together and the dimensions of the stud. This is true of the time and pressure needed as well, but the current needed will vary more greatly in direct reliance on the metals used.
  • Materials used: Because time, pressure, and current change based on the materials used, those metals are a critical specification to take into account if you want to create a strong weld connection with a CD tool. Effective CD welding can be used to weld low carbon steel, mild steel, stainless steel, aluminum, brass, or alloys specifically formulated for CD stud welding.

 

CD stud welding can be the key to open many manufacturing doors if you have the information you need to determine what studs to use and what to calibrate your tools to. Find our CD welding stud and CD weld pin selection online or contact us to request customized stud dimensions.

 

To learn more about the stud welding processes, contact Northland Fastening Systems today at (651) 730-7770, or request a quote online to get started.

Polarity and Current for Weld Fastening Systems

Posted on by norfas by norfas

From ship building to composite thru-deck welding, stud welding is a simple operation used in many complex construction projects. The process of stud welding is a relatively new one, with a history dating only back to the turn of the 19th century. The newness of stud welding fastening systems is largely due to its use of electricity as a sole power source and arc generator. Because of this, the polarity and current supplied to a stud welding unit must be perfectly calibrated for the tool, stud, surface material, and weld circumstances.

 

If you are using stud welding to complete a project, you can rely on Northland Fastening Systems for all your studs, tools, accessories, and service needs. We provide a comprehensive selection of everything needed for stud weld fastening systems and expert technical support to customers worldwide.

 

If you are working with a stud welding unit and calibrating that tool for the weld you need, it’s important to understand the role of polarity and current for drawn arc and capacitor discharge (CD) welds.

 

Polarities

Every electrical current has a polarity that is either positive or negative. There are types of stud welding tools that use either polarity, but choosing which tool and polarity depends on the stud, the welding operation, and the surface material of what you will connect the stud to. Negative-electrode polarities are also referred to as “straight,” and positive-electrode polarities are also called “reverse” polarities. Positive polarities offer a weld with deeper penetration into the surface material. A reverse polarity weld is suitable for heavy-duty welding with larger studs. Negative polarities, on the other hand, offer a quick-melt weld with faster deposition rate, making it ideal for stud pins and rapid construction.

 

Currents

The pattern of electrical currents will also affect the weld results. Currents will move in negative or positive polarities directly or in alternating patterns between the two. Direct current (DC) welding paired with the correct shielding gas offers a smoother, cleaner weld thanks to a stable arc. DC welds also limit splatter in the weld. Because of this, most professionals use DC welding currents with either positive or negative polarities.

 

In some cases, however, alternating currents are more suitable. Beginners may choose AC welding tools that tend to be less expensive and easier to use. Alternating currents change polarities around 120 times per second with 60 hertz currents. AC welds are also used heavily in shipbuilding because the movement of the ship in construction may cause an arc to blow side-to-side.

 

Find the Right Fastening System Today

If you are using stud welding as one of your fastening systems in any given project, choosing the right polarity and current type is critical to performing an accurate, clean, and strong weld. To learn more about stud welding specifications or to find everything you need for studs, tools, and accessories, contact Northland Fastening Systems at (651) 730-7770, or request a quote online to get started with us today.

AC vs. DC Polarities in Stud Welding

Posted on by norfas by norfas

Stud welding is a manufacturing application that is made possible by electricity. Before the development of electrical currents into various systems usable by individual consumers and businesses alike, the only format of welding possible was the ancient technique of forge welding. With the use of electrically generated currents, stud welders can create a bond between the stud and surface material that is stronger than either metals put together. If you are using stud welding on site, Northland Fastening Systems (NFS) can provide anything you might need, including welding studs, welding units for rent or purchase, and welding accessories for both drawn arc and CD stud welding.

 

When it comes to stud welding, there are two electrical current polarities that can be used depending on the welding situation and tools used: alternating current (AC) and direct current (DC). For the most part, DC polarities are used in almost every stud welding application. However, there are some instances when AC polarities are necessary and advantageous.

 

DC Polarities in Stud Welding

 

DC polarities move in what is essentially a straight line. The electrical current, whether positive or negative, flows directly from the power source through the tool and is applied at the weld site in either a capacitor discharge weld or a drawn arc current. DC welding is typically used because it provides a more controlled weld with a smoother arc that is stable and predictable. Positive DC welding performs a higher penetration into surface material for heavy-duty welding studs, while negative DC welding has a lighter penetration but greater deposition for effective welds on thin sheet metal.

 

AC Polarities in Stud Welding

 

AC polarities have a balanced transition between positive and negative direct currents throughout the application. Because of this, AC welding is beneficial over DC if you need lower penetration and an overall different type of weld. AC welding is a secondary option if the location of the worksite only offers that type of current, but it is also used in specialized welding processes such as welding magnetized materials. In addition, AC welding is used heavily in ship building, repairs, and other projects that need rapid, easily portable welding tools. However, AC welding often has a great splatter and is a messier weld than DC stud welding.

 

Learn More from Northland Fastening Systems

If you are using stud welding of any kind on your worksite, Northland Fastening Systems can help you determine whether AC or DC welding is a better option. For more information about polarities  or to find a comprehensive selection of equipment, contact us at (651) 730-7770. You can also request a quote online to get started with our team of expert technicians today.

The Use of Ceramic Ferrules in Drawn Arc Stud Welding

Posted on by norfas by norfas

Stud welding is a widely used manufacturing operation for connecting various components, support structures, assemblies, and composite construction. While there are many applications for various types of stud welding, drawn arc stud welding in particular is used for heavy-duty construction using studs with dimensions typically larger than ¼”. Drawn arc welding studs also utilize a ceramic ferrule in the bonding process. This ferrule helps create a bond that is stronger than both the welding stud and the material being welded to. When you work with Northland Fastening Systems for all your drawn arc stud welding projects, you have access to all the high-quality studs, welding tools, and accessories you need.

 

Working with a ceramic ferrule to establish strong bonds using the drawn arc stud welding process requires specific tools and practices including a drawn arc gun and calibrated unit, drawn arc studs, ceramic ferrule sized correctly, and an adequate power source.

 

How it works: The ceramic ferrule works to surround and contain the welding stud during the weld. As the drawn arc current heats the tip of the stud and the metal becomes molten, the ring-shaped ferrule keeps the metal from spreading into a messy weld. The ceramic ferrule also protects the weld from exposure to oxygen in the air. Oxygen exposure can lead to porous or weakened welds. Additionally, the ferrule creates a protective barrier reducing UV exposure. Once the weld is complete, the ferrule is chipped away leaving a clean, perfectly formed weld.

 

Ceramic ferrules are required for drawn arc stud welding because the process is a longer weld time than other welds, the welding studs are typically thicker in diameter, and the weld will be required to hold greater weights than other welding formats.

 

Short cycle welding uses inert shielding gas instead of ceramic ferrules, and CD stud welding uses a different process entirely that doesn’t have the risk of molten metal spread. Instead, CD welding uses an exact combination of pressure and current frequency to heat the metal stud and bond it to the surface material.

 

If you’re working with drawn arc stud welding operations on your job site, Northland Fastening Systems can provide all the studs, accessories, and welding tools for rent or purchase you might need from the start of your project to the finish.

 

To learn more about drawn arc stud welding and the use of ceramic ferrules, contact Northland Fastening Systems today at (651) 730-7770, and feel free to explore our selection of drawn arc welding studs or other items online or request a quote.

Inspection Practices for CD Stud Welding Quality

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Stud welding of all types can be one of the most effective manufacturing operations in a wide range of industries when it is applied correctly. While drawn arc welding is key for large-scale construction with heavier studs, capacitor discharge (CD) stud welding is an excellent operation for clean, rapid welds used in lightweight construction or smaller assemblies. With Northland Fastening Systems (NFS), you can find studs for drawn arc and CD stud welding in all dimensions, a comprehensive selection of welding tools for rent or purchase, complete welding accessories, and the expertise of our skilled welding technicians. An important part of any stud-welding operation that our technicians can provide guidance and support for is the weld inspection process.

 

The weld inspection process for CD stud welding can take several steps depending on factors of the weld condition, the stud dimensions, and the materials used. The two primary methods of inspecting the quality of a CD weld connection are visual and mechanical diagnostics.

 

Visual Diagnostics: To inspect a CD weld visually, there are several conditions a welder should look for. First, if there is any splattering of the metal, the weld may be weakened due to a too-hot weld. Next, look for a lack of metal melted around the base of the stud. Too little metal shows the weld was cold. Additionally, if there is any reverse-side marking on the component opposite the weld, there may have been too much pressure or heat during the weld. Finally, if the stud is indented or sunk into a divot in the base material, the stud is weakened by too much pressure or heat in the weld.

 

Mechanical Diagnostics: Mechanical inspections depend entirely on several aspects of the weld. This includes the stud dimensions, the material of the stud, the material of the base material, the thread size of the stud, the time and pressure of the weld operation, and the heat/voltage of the welding tool. To determine the yield load, ultimate tensile load, yield torque, ultimate torque, and shear strength of any CD weld, all the preceding listed aspects of the weld must be taken into consideration.

 

To perform a weld successfully with long-term reliability, both visual and mechanical inspection practices must be put in place in your production process. With the comprehensive supply of CD stud welding and drawn arc stud welding tools Northland Fastening Systems has available, you can implement stud welding into your operations. Contact NFS at (651) 730-7770 today, or request a quote online to get started with us today.

Why International Certification Is Important for Stud-Welding Equipment

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At Northland Fastening Systems, we’re committed to providing excellence in all areas of our services and stud-welding equipment that we offer. Our comprehensive selection of welding studs, stud accessories, welding tools for rent and purchase, and all other stud-welding equipment meets national and international standards for the stud-welding industry. Not only do our services and products meet the International Organization for Standardization’s requirements for an ISO certification, we also meet Quality Assurance Standards (QAS) International standards for practices and stud-welding equipment.

 

Our ISO 9001:2015 certification for international excellence is a mark of our dedication to upholding industrial standards of quality for both our practices and all the stud-welding equipment we offer to our customers. Our current certification was granted through QAS International, a certification company working in global industrial markets. Our international certificate of quality means our practices meet worldwide standards for quality, precision, reliability, safety, and customer care.

 

An international certification means several pluses for NFS, including the improvement of quality and expertise for many parts of the stud-welding industry.

 

Other pluses include improvements to:

  1. Productivity: Manufacturers that work with NFS find that our reliability, quality of product, and technical expertise improve their own productivity. Both project management and fabrication practices are streamlined and improved when our customers have access to our services and products.
  2. Waste Reduction: Our customers also see a decrease in waste generated from the start to finish of any project. Our professional guidance and superior products dramatically reduce time and money spent on repairing or repeating welds.
  3. Quality Control: Thanks to improvements in productivity and waste reduction, manufacturers can dedicate more time to quality control, including testing, diagnostics, troubleshooting, prototyping, and real-time function simulations.
  4. Workplace Safety: In addition to more time for quality control, customers working with NFS can also put more energy into improving their workplace, expanding workplace safety, and overall increasing the morale and motivation of their team members.
  5. Customer Satisfaction: Because of the motivation of staff, improvements to production, and quality of product, customer satisfaction from our customers to theirs is increased. The service and products all customers receive is better, and they are happier thanks to our international certification.

 

The internationalization of stud-welding standards and industrial standards overall makes a more specific outline of what manufacturers need to do to meet the highest caliber of service and product. Starting with our ISO certification and an internationally recognized quality of product and service, we can all work together to improve the industrial world as a whole. To learn more about the stud-welding equipment and services we offer, contact NFS at (651) 730-7770 today, or request a quote online to get started with our team now.

Avoiding Common Defects with CD Stud Welding

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Stud welding is an operation that many industries utilize because of its diverse benefits to a wide range of production processes. While drawn arc stud welding is key for heavy-duty studs, load-bearing composite building, and other large-scale construction, CD stud welding has an equal frequency of use in different types of construction.

 

If you’re using CD stud welding in your production process, you will gain the benefits of rapid, economical, low-energy welding that provides a clean weld with no reverse-side marking. With the help of Northland Fastening Systems technical support and our selection of all the tools, studs, pins, and accessories you might need for CD stud welding, you can get your job done with ease and quality.

 

CD stud welding is a form of resistance welding, unlike drawn arc welding. Arc welding is a fusion welding process that often requires a filler material and frequently leaves a slag from the flux used that has to be cleaned to finish the product. CD stud welding doesn’t require a filler material and it leaves a clean weld that won’t need finishing after the weld is done.

 

When done correctly, CD stud welding is a fast and easy process that leaves a pristine, strong weld. However, there are some defects that can occur when CD stud welding is not performed accurately or with the right materials:

 

  • Spread of molten metal from the weld site is a common issue when weld pressure is too low, the current is too high, or the weld is timed incorrectly. Molten metal expulsion can also be evidence of surface contamination.
  • Spattering of metal is another sign of too high a current. It creates excess heat that can cause explosive spray and loss of metal at the weld site, weakening the weld overall.
  • Cracked weld connections are a clear alert to a weak weld. These cracks often occur due to lack of pressure during the weld leading to an incomplete or porous connection. Inadequate pressure during the weld leads to a low tensile strength at the connection point.
  • Indentations at the weld site are another result of incorrect pressure and/or current. With too much pressure, the current decreases and a poor weld connection is formed because of the low pressure. Welding studs indented into surface material even slightly are a sign of too high of pressure and too low of current/temperature.
  • Misshapen weld spots are also a common defect with incorrectly performed CD stud welding. A strong, accurate weld should have a perfectly circular weld mark. Bloated, smushed, or otherwise misshapen weld spots are a result of contamination or misaligned electrodes in the welding tool.

 

These defects can be easily avoided when you choose to work with NFS products and take advantage of our technicians’ expertise whenever questions arise. To learn more about our CD stud welding products and other stud welding supplies, contact NFS at (651) 730-7770 today. Request a quote online to get started on your stud welding project now.

 

Glossary of Terms for Stud Welding

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For any builders, fabricators, or manufacturers who are just beginning to use stud welding operations as a tool in their work, there is a lot to learn. While stud welding appears to be a relatively simple, straightforward operation, there are many complexities about the varying types of processes. At Northland Fastening Systems, we offer a comprehensive supply of stud welding tools, studs, and accessories in addition to our expert technical support services. If you are a beginner or even an experienced stud welder, our team of skilled service technicians can provide the support and tools that you need to get the job done.

 

If you are just beginning to work with stud welding tools and processes, it’s important to understand the basic terms used to describe aspects of the operation. Some of the most important, widely used terms in the stud welding industry include:

 

  1. Stud: Any fastener used in the stud welding process. This includes pins, shear connectors, and bar anchors as well as standard studs. Studs can be made from steel, aluminum, brass, copper, or related alloys.
  2. Gun: The hand-operated tool used by the technician performing the weld. Studs are inserted in the tip of the gun and applied to the surface that it will be welded to.
  3. Controller: The electrical unit controlling the supply of voltage to the welding gun or welding tip. The controller used depends on the type of welding process, the stud dimensions, and the material to be welded to.
  4. Parent material: The surface material that the stud will be welded to. This is also called the “workpiece.” If done correctly, the bond between the stud and the parent material will be much stronger than the stud or parent material alone.
  5. Capacitor discharge (CD): A type of stud welding process that uses electrical discharge heat to connect the stud to the parent material. CD stud welding is fast, cost-effective, and clean.
  6. Drawn arc: Another common type of stud welding. The process uses an arcing current to heat the stud inside a ceramic ferrule while it is held against the parent material. This process is suited for welding heavy-duty studs with larger diameters.
  7. Ceramic ferrule: A ceramic containment piece for the stud used in a drawn arc process. It serves to regulate the weld temperature and prevent the molten metal from moving outside a desired range.
  8. Chuck: A component that holds a stud in the tip of the welding gun during the CD stud welding process.
  9. Flux: An aluminum coating on the tip of a drawn arc welding stud. It improves the ignition and de-oxidizes the pooling of the weld point.

 

There are many other terms used for different components of various welding processes, but this list covers the basic vocabulary used in most stud welding operations. To learn more about stud welding and the tools or terms used, contact Northland Fastening Systems at (651) 730-7770 or request a quote online today.

 

 

 

 

 

Application of Shear Connectors in Thru-Deck Stud Welding

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Stud welding is a versatile process with many industrial applications. While stud welding is often primarily used in exterior or visible interior installations, it is also a key operation for large-scale construction. Shear connectors and other anchor bar systems provide necessary strengthening of a structure and critical support against stresses. If you are fabricating a system with metal decking or other weld-thru metal structures, Northland Fastening Systems (NFS) can provide the shear connectors, anchor bars, welding tools, and any other studs or accessories you need to get the job done. When it comes to thru-deck stud welding operations, NFS offers the technical support and tools needed.

 

Composite construction applications like thru-deck welding requires careful consideration of each material used in the process and understanding of the process itself. When it comes to the composite building of structural beams, galvanized decking, and concrete, shear connectors welding studs are key for long-term structural integrity.

 

The included image shows a three-dimensional cross section of a weld-thru decking application. The shear connecter studs welded directly through the galvanized decking material fasten it to steel I-beams. A rebar webbing is overlaid for support and flexibility of the final layer of concrete finishing the composite system. As a complete decking system, this composite structure can be utilized in a range of applications, but is primarily used in the construction of multilevel buildings with steel beam skeletons.

 

The use of shear connector welding studs is critical in this type of composite construction system. If you are working with thru-deck weld construction processes, NFS can provide comprehensive shear connectors in varying dimensions, including stud diameter and length.

 

For general-purpose thru-deck composite welding, our shear connector studs have a minimum tensile strength of 61,000 psi (420 MPa) and a minimum yield strength of 49,000 psi (340 MPa). For shear connectors that will be used in composite beam construction like the processes used in multilevel buildings, our specialized studs have a minimum tensile strength of 65,000 psi (450 MPa) and a minimum yield strength of 51,000 psi (350 MPa). NFS also offers custom lengths for both types of shear connectors with any of our available diameter.

 

Not only do the connector studs fasten galvanized decking to structural beams, they are also key in shear load bearing. The minimum tensile and yield strength of each stud works together to support entire buildings upward of 100 stories. The system of a composite beam construction increases the flex range and support strength of the building as a whole, which allows it to react to movements of the earth plates, the wind, and other natural elements; weight inside the building; and changes in molecular size with temperature shifts. In every composite structure, shear connectors are key components.

 

To learn more about weld-thru decking and the use of stud welding in composite construction, contact NFS at (651) 730-7770 today, or request a quote online to get started with us today.