Author: norfas

Drawn Arc Stud Welding Highlights from Start to Finish

Posted on by norfas by norfas

Drawn arc welding is a complex process made simple with today’s technology. Though welding has been around for centuries, beginning with the oldest forge welding to today’s capacitor discharge welding, it hadn’t begun development into the highly advanced process contemporary welders use until the late 1970s. Thanks to the advancement of welding techniques since then, we are able to utilize both drawn arc and capacitor discharge processes to perform stud welding operations. If you are working on a CD or drawn arc stud welding project, Northland Fastening Systems has everything you need from tools for rent and sale, studs of all shapes and sizes, stud welding accessories, and our own welding services.

 

When it comes to the traditional format of drawn arc stud welding, there are several stages of the procedure to take into consideration. First, the welding operation itself, which follows a simple step-by-step process:

 

  1. The welding gun is set onto the base material at the desired weld point and the operator compresses the main spring partially.
  2. The trigger is then compressed, and the stud is lifted magnetically from the base material to create an arc.
  3. The arc melts the stud tip and the base material while a ceramic ferrule shield concentrates the heat, containing it to one weld point.
  4. The stud is then compressed into the base material, melding the two molten metal components.
  5. The welding gun releases the stud, the ferrule is broken, and the welding process is complete.

 

A drawn arc stud welding process creates a bond that is stronger than the stud itself. As welding processes go, drawn arc welding is one of the most effective, fastest, and strongest operations for stud welding manufacturing. For even more effective, accurate drawn arc stud welding, templating is a highly useful procedure.

 

Templates improve the accuracy of a welding operation that uses a ceramic ferrule to contain the heat during the arc. Steel plates hold the ferrule in place, while spacers allow the gasses from the weld to escape through gaps underneath the template plates. Additional template options may allow tube templates with ventilation holes to hold the ferrule, or brushing templating can be applied.

 

Brushing templates allow for angled alignment of the stud in addition to an exact location. These templates use a tube adapter to sheath the stud and tilt it to the desired angle. The tube adapter is connected on one end to a foot component that can be attached to the welding gun and on the other to the ferrule. Template brushing components made from masonite or ebonite are stationed between the template and the tube adaptor. These components protect your template’s longevity and improve the accuracy of the weld. Virtually all drawn arc welding operations benefit from the use of a template.

 

To learn more about drawn arc stud welding and our additional services for stud welding, contact Northland Fastening Systems at (651) 730-7770 today.

 

The Flexibility and Quality of Stud Welding

Posted on by norfas by norfas

Centuries ago, forge welding was developed and used for many manufacturing applications. In the late 19th Century, arc welding was developed as electricity became standard throughout manufacturing industries. All welding formats quickly advanced during the world wars as demand for fast, cost-effective attachment methods grew immensely. After WWII, many additional welding techniques were developed, including capacitor discharge (CD) welding.

Since the expansion beyond forge welding in the late 1800s, stud welding has remained a constant in the welding world, developing alongside other welding applications. Historically, stud welding was used primarily for shipbuilding, but because of its versatility and adaptability, it is used in a wide range of global industries today.

 

Northland Fastening Systems is committed to providing every aspect of services and tools needed to open the doors to everything stud welding can do with its flexibility and quality results. From tools and accessories to our own stud welding services, NFS is your one-stop-shop for all the supplies you need to complete any project, big or small.

 

Access to a wide range of stud welding supplies is critical because of the versatility of its manufacturing applications. In fact, stud welding is one of the most flexible welding operations used in any given industry, and it provides a clean, quality weld point that is even stronger than the materials welded together. This flexibility is due to several factors, including:

 

  • Adaptability: Stud welding units can be adjusted to weld studs made from different materials to a wide range of surface metals. Studs themselves come in a range of dimensions including diameter, length, and thread variations. The shape of the stud is adaptable, and several additional options are available for stud properties. Overall stud welding can be used in almost any operation where studded surfaces or other forms of stud connection are necessary.
  • High-speed: Stud welding cuts the time of other stud connection methods in half, making it one of the fastest manufacturing operations available. Handheld stud welders can perform up to 20 welds per minute when used manually, and some automated systems can perform upwards of 60 welds per minute.
  • Maneuverability: Stud welding guns are small, moveable tools that can be used in cramped or difficult-to-reach spaces. Additionally, welders only need access to one side of the weld point, making surface welding faster and more easily maneuvered.
  • Portability: Stud welding units are lightweight in comparison to other welding equipment. Units can be moved with ease between worksites, and many units are designed specifically for constant movement on the job.
  • Weld results: Stud welding is one of the cleanest welding operations available to any industry. Stud welders create a clean, one-sided weld point without holes, residue, or marking. This clean weld improves the strength and extends the lifetime of the weld point and the product overall.

 

Contact Northland Fastening Systems today at (651) 730-7770 or request a quote online to get your next project started right!

 

Technical Specifications and the Engineering of Stud Welding

Posted on by norfas by norfas

As one of the most versatile and widely used fastening systems, stud welding is an invaluable operation for a broad range of manufacturing industries. Because of its wide range of uses, stud welding has to meet a large number of engineering specifications, such as sizing, strength, materials, format, and process specifications. For any stud-welding project specifications, Northland Fastening Systems provides services and offers equipment, studs, accessories, and everything you need to get the job done.

 

Stud welding can be performed with drawn arc welding or CD welding units that vary in sizes, portability, and capability. Though both drawn arc and CD welding are rapid operations that provide a weld connection stronger than the stud and surface material combined, they differ in several ways when it comes to the engineering specifications.

 

Drawn Arc Stud Welding

  1. Materials used:
    1. Low-carbon steel with tensile strength of 60,000 psi minimum, a yield strength of 50,000 psi minimum, and a 20% minimum elongation in 2 inches. When annealed, the tensile strength becomes 50,000 psi, yield becomes 35,000 psi, and elongation becomes 25%.
    2. Stainless steel with tensile strength of 85,000 psi minimum, a yield strength of 40,000 psi minimum, and a 45% minimum elongation in 2 inches.
  2. Stud fastening torques:
    1. For low-carbon steel with studs ranging from 8-32 to 1”-8: between 17.8 and 2831 lbs per inch.
    2. For stainless steel with studs ranging from 8-32 to 1”-8: between 19.8 and 3440 lbs per inch.

 

CD Stud Welding

CD welding studs use a variety of materials from steel to brass. Each stud material provides a successful weld that is dependent on the base material. Some are more suited to a base material than others. For example:

  1. Mild steel:
    1. Excellent when welded to other mild steels, galvanized sheet materials, structural steel, stainless steel, and lead-free brass, rolled copper, and electrolytic copper
    2. Good when welded to medium-carbon steels and die-cast zinc alloys
    3. Cannot be welded to common aluminum alloys
  2. Stainless steel:
    1. Excellent when welded to mild steels, galvanized sheet materials, structural steel, stainless steel, and lead-free brass, rolled copper, and electrolytic copper
    2. Good when welded to medium-carbon steel and die-cast zinc alloys
    3. Cannot be welded to common aluminum alloys
  3. Aluminum:
    1. Excellent when welded to die-cast zinc alloys and common aluminum alloys
    2. Cannot be welded to mild steels, galvanized sheet materials, structural steel, stainless steel, and lead-free brass, rolled copper, or electrolytic copper
  4. Brass:
    1. Excellent when welded to mild steels, structural steel, stainless steel, and lead-free brass, rolled copper, and electrolytic copper
    2. Good when welded to medium-carbon steel and die-cast zinc alloys
    3. Cannot be welded to galvanized sheet materials and common aluminum alloys

 

Learn more about engineering specifications in the stud welding industry with Northland Fastening Systems. To get started with us today, call (651) 730-7770 or request a quote online.

Benefits of Copper Plated Studs for CD Stud Welding

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Copper is a unique metal in many ways, from its rich coloring and conductivity to its resistance to corrosion, despite a quick oxidizing of the outer layer. Exposed to tarnishing conditions, the warm orange-brown of copper eventually becomes the green patina many sculptors and builders desire. In addition to its range of cosmetic uses, copper is also highly useful for many industrial and otherwise practical applications.

Because of its electrical conductivity, copper wiring and other components are frequently used in electronic applications, but it’s also used extensively for specific manufacturing purposes. For example, Northland Fastening Systems uses copper plating for many studs used in high-quality CD stud welding and offers copper plated studs for sale ranging in length, diameter, and threading.

CD stud welding is a highly effective manufacturing process for clean, strong, rapidly-made connection points between the stud and the base surface. Not only is CD stud welding well-suited to fabricating food service equipment, electrical enclosures, construction welding, and much more, it’s also widespread in shipbuilding, automotive manufacturing, and countless other types of large-scale construction. Copper plated studs are frequently beneficial for use in these stud welding operations for several reasons, including:

  • copper’s conductivity provides a clean, highly rapid weld as a plated surface
  • its overall resistance to corrosion in comparison with non-plated steel studs
  • its improved electrical conduction for specific applications
  • its ability to slow or prevent alloyed elements from migrating
  • in some applications, copper plating improves solderability
  • it extends the dimensional tolerance of the stud
  • copper plating can improve the service life of any given weld and stud itself

 

Copper plating for our CD studs is standard, including studs made from aluminum, mild steel, and brass. Both flanged and non-flanged studs benefit from copper plating in dimensions ranging from:

  • 2-56 to ⅜-16 stud diameter
  • .125 to .437 flange diameter
  • .250 to .500 minimum stud length
  • ⅝ to 2-½ full stud length
  • 4-40 to ⅜ – 16 threading

 

CD stud welding is an excellent operation for such a wide range of applications that it’s become a constant for many contract manufacturers and construction crews as well as a useful tool for stud welding specialists. Copper plating opens an even wider range for stud welding, and at NFS you get the best of both worlds. In addition to CD stud welding tools for rent and purchase, we offer a comprehensive variety of studs for CD welding, drawn arc welding studs, drawn arc tools, and automation equipment.

 

To learn more about CD stud welding and copper plated studs, contact Northland Fastening Systems at (651) 730-7770 today or request a quote online.

The Importance of the Stud Welding Process in the U.S. Navy from WWII to Today

Posted on by norfas by norfas

For years, the stud welding process has been used for fabrication of all kinds of large-scale construction projects, including a high prevalence and cruciality to the shipbuilding industry. Despite the importance and well-documented use of stud welding in the maritime industry today, it wasn’t always such a highly prominent fabrication process. In fact, it wasn’t until the U.S .Navy’s use of stud welding during World War II (WWII) that the world began to recognize the stud welding process as a superior manufacturing operation for stronger, faster, lighter, and longer-lasting ships. Whether you are a player in the maritime industry or are working on a smaller scale project, Northland Fastening Systems has everything you need to complete the stud welding process from start to finish, including stud welders, studs, accessories, and our own stud welding services.

 

Stud welding was one of the most important manufacturing processes for shipbuilding and the U.S. Navy in WWII. Although stud welding was commonly used in shipbuilding since the early 1900s, the results were still creating warships, freighters, and other large vessels that were heavy, slow, and required an excess of materials. By the 1930s, the United States realized it needed a strong marine and naval force to protect the country.

 

In the face of the war and a lackluster maritime presence, the U.S. Congress passed the Merchant Marine Act in 1936, which helped both U.S. merchant ships and the U.S. Navy revolutionize their maritime presence, almost completely thanks to the act’s requirement of improved ship construction. To meet this requirement, a stud welding technique that the American Welding Society and the New York Navy Yard developed in 1930 was vital.

 

This stud welding technique provided a way to connect wood directly to steel. The new ships built in accordance with the Merchant Maritime Act relied heavily on this technique and other stud welding processes to build ships unparalleled by any other navy at the time. In many ways, stud welding helped the United States and its allies win WWII.

 

Since the use of stud welding processes in shipbuilding during WWII, naval and merchant vessels have benefited from huge advancements in welding units, welding guns, studs, and other stud welding techniques. Even today, with the range of futuristic manufacturing capabilities, stud welding is a staple for maritime industries.

 

To learn more about the use of stud welding processes in shipbuilding and many other industries, or to get the supplies you need, contact Northland Fastening Systems at (651) 730-7770 or request a quote online today.

Old and New Uses of Stud Welding Equipment in Shipbuilding

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The use of stud welding for shipbuilding and other maritime construction is as old as the welding process itself. As far back as the turn of the 19th century, simple forms of stud welding were developed for various shipbuilding purposes.

 

By the end of WWI, stud welding began to play a more significant role for industrial shipbuilding of trade and military vessels. Many wars and technological advancements later, stud welding remains a primary manufacturing operation for shipbuilding large and small. Northland Fastening Systems provides a wide range of reliable, high-quality stud welding equipment suited for any type of shipbuilding projects and other construction welding.

 

From portable automated welding units to highly specified welding studs, NFS has everything you might need for even the largest shipbuilding project. The history of shipbuilding was revolutionized by the development of stud welding procedures suited to the fabrication of seaworthy vessels and other marine components. Today, both drawn arc and CD stud welding are used in a wide range of shipbuilding operations. Some of the most prevalent of these operations include:

 

  • plating hulls and protecting or streamlining other exteriors
  • building decking, bulkheads, and other interior structures
  • fittings including portholes, hatches, or storage units
  • pipe and cable hangers and protection units
  • manhole fittings, winches, ladders, and other functional accessory components
  • propellers, rudders, steering shafts, masts, and other locomotive components
  • connecting lining and wedging joints, anchoring equipment, shell plating, and ceramic backing
  • performing repairs at sea

 

In a nutshell, a broad majority of shipbuilding operations rely on stud welding. Technicians working on shipbuilding projects can find all the stud welding equipment they need with Northland Fastening Systems. Our stud welding technicians provide CD and drawn arc welding services and guidance, and we offer stud welding equipment including stud welding units and welding guns for sale or rent, welding studs for CD and drawn arc welding in a variety of metals, sizes, and other specification, and any other stud welding accessories you may need.

 

Stud welding operations used in shipbuilding and maritime manufacturing contributes to the construction of small boats for personal use, small to large boats for police, forestry, and coast guard purposes, long-haul freighters and milk truck delivery boats, submarine research vessels, pleasure cruise ships, armed military vessels, aircraft carriers, and many other types of sea and freshwater ships.

 

To learn more about the use of stud welding for shipbuilding and other marine construction purposes, contact Northland Fastening Systems at (651) 730-7770, or to find out more about the stud welding equipment we offer, contact request a quote online.

Suitable Materials for Welding and Finding What You Need with NFS Stud Welding Supplies

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Metalwork is one of the most important methods of manufacturing for a wide range of construction and production industries. As a part of metalworking as a whole, stud welding has its own place of import in many types of fabrication. From metal equipment manufacturing of all kinds to large-scale construction, stud welding is utilized in the fabrication of many shapes and sizes. If you are working on a project that requires the use of stud welding for clean, quality building, Northland Fastening Systems (NFS) is your one-stop shop for quality stud welding equipment, including tools for rent and purchase, studs fitting all size, thread, and material needs, and stud welding accessories. As a leading industry provider of stud welding supplies locally and globally, NFS has what you need for any project, no matter how complex.

 

While the material used in welding is most often a steel composite, there is a wide variety of additional alloys that are effective for many welding circumstances. From aluminum to copper, stud welding can be performed with several different quality materials.

 

Stud Welding Metals

 

  1. Stainless steel: One of the most commonly used stud materials, stainless steel offers a greater resistance to corrosion. Stainless steel studs are also highly durable and can take many finishing and treatment applications, such as annealing or plating. Both drawn arc and CD stud welding studs can be made from stainless steel.
  2. Mild steel: Also suitable for both drawn arc and CD stud welding, studs made from mild steel alloys are available with a range of properties. Alloys can be made for greater heat resistance, strength, durability, corrosion resistance, acid resistance, flexibility, and more.
  3. Aluminum: Aluminum studs are useful when welding to aluminum bases. NFS offers studs made from aluminum alloys for CD stud welding with options for three different alloy compositions. These alloys vary in properties and provide different fits for different projects.
  4. Brass: CD stud welding can also utilize brass studs. These lead-free brass studs can be welded to a similar brass alloy base or to a lead-free copper alloy base.
  5. Copper: While not typically used as a material for the stud alone, copper can be key when used to plate a CD welding stud. NFS offers copper plating as a standard option for low-carbon steel studs to improve thermal and electrical conductivity from stud to surface.

 

No matter what project you need stud welding to complete, NFS has the stud welding supplies compatible with your welding tools and the base materials you need to weld. Specifications for materials, length, diameter, threading, flanging, plating, annealing, and more are all available to customize your order to the perfect fit for your fabrication requirements.

 

To learn more about the materials and other stud specifications we offer, or to learn about the stud welding tools, welding guns, accessories, and other stud welding supplies Northland Fastening Systems provides, contact us at (651) 730-7770. You can also request a quote online to get started working with us today.

 

Physical Effects of Stud Welding and the Advantages of Automation

Posted on by norfas by norfas

Stud welding is a fabrication technique that is critical to a wide range of manufacturing industries. Not only is it used in equipment manufacturing of all shapes and sizes, it’s also an important part of building construction and other large structures. Because of the immense prevalence of stud welding in the industrial world, it’s important to have access to quality stud welding equipment, studs of all dimensions and materials, and comprehensive accessories. That’s why Northland Fastening Systems provides everything fabricators need for their stud welding projects and services.

Stud welding, though an effective and widely versatile fabrication method, requires a lot of repetitive motions. Technicians often perform more than 1,000 welds in one day on the job, and the repeated motions involved in the process can take a physical toll. However, this effect is not the only impact that welding technicians experience with long-term stud welding work.

 

Impact of Prolonged Stud Welding

Stud welding technicians are exposed to two types of potential physical harm:

  1. Physical stress from the bending motions of welding many studs repeatedly
  2. Various health risks from the fumes created in the welding process

Of these two, the fumes created with each stud weld operation is an issue addressed less often than it should be. The heat and pressure of both drawn arc and CD stud welding operations creates a plume of respirable metalloid particles small enough to be forced into a radius of approximately 12-20 inches. These plumes can contain zinc, nickel, iron, copper, manganese, chromium, cobalt, lead, and more, depending on the welding materials.

Many welding technicians wear little-to-no breathing protection, and because of this may be at greater risk for lung cancer, metal fume fever, pneumonia, and bronchitis. Some studies have also shown that welders exposed to welding fumes over extended periods of time may be at greater risk of developing Parkinson’s disease. Despite this danger, there are many ways to minimize the potential of physical damage from the fumes and the welding process itself.

 

How Automation Can Protect Your Welders

Automated stud welding offers many solutions for preventing or limiting health risks and physical long-term effects many welders experience. NFS offers automation capabilities that can change the way your welding technicians perform their tasks. Stud welding units that are automated can greatly reduce the need for technicians to perform repeated physical movements to establish a weld connection. Automation also often removes the welding technician’s breathing zone from the dangers of the welding plume. Limiting the exposure to fumes and the time spent performing repetitive motions can significantly reduce physical harm to your stud welding technicians. NFS provides a wide range of automated stud welding equipment, including units that can withstand harsh environments.

 

Protecting your workers and streamlining your stud welding production starts with automation. Get started with Northland Fastening Systems today and contact us at (651) 730-7770 to learn more about minimizing the health risks of stud welding and the benefits of automation.

Fabricating Clean Electrical Enclosures with Quality Stud Welding

Posted on by norfas by norfas

Northland Fastening Systems (NFS) utilizes the capabilities and benefits of stud welding operations for a wide range of manufacturing purposes. We also provide stud welding services for a variety of industries, offer stud welding tools for rent and sale, and sell a comprehensive assortment of studs and accessories.

Because of the versatility stud welding offers in so many fabrication processes, it’s a valuable option for many projects, big or small. With our variety of products, tools, and stud welding services, NFS is a fully outfitted provider for all stud welding manufacturing requirements in the U.S. and worldwide. If you’re looking to get started on your stud welding and need direct access to all you need at one friendly location, look no further than NFS.

The range of different applications that stud welding is suited to casts a wide net over industrial and small-scale manufacturing. When it comes to fabricating components for electronics, stud welding is a primary source for manufacturing durable, specialized electrical enclosures.

 

What are Electrical Enclosures?

Electrical systems are powerful tools for many purposes, from directing and storing current to computing the trajectory of a space shuttle. Despite their powerful capabilities, electronics themselves are often fragile systems with little defense against liquids, extreme temperatures, lights, and many other stresses. Because of their vulnerability overall, electrical enclosures are critical components in the majority of systems.

Electrical enclosures are essentially cabinet units that protect and store electrical systems. They can range from simple box units made from aluminum to ruggedized, highly durable enclosures built with weather-resistant alloys. Enclosures can be standardized to a specific range of electrical setups or they can be specialized to a fit a uniquely designed electrical unit.

For all types of electrical enclosures fitting all types of electrical systems, stud welding is an extremely useful method of construction for several reasons:

 

  1. Stud welding creates a clean weld without a mark on the surface opposite to the weld
  2. Using high-quality studs and welding tools creates a strong weld connection
  3. Certain stud types can be fabricated for controlled conduction of electricity
  4. Welds can be created on the interior of an electrical enclosure for a clean, mark-free exterior
  5. Stud weld connections bind greater areas of a surface than other types of welding
  6. Enclosures made with stud welding can be fabricated with a wide range of materials
  7. Stud welding offers a rapid build process without sacrificing quality

 

For any size or shape of electrical enclosure, stud welding is a great choice for a clean, seamless, finished look. To learn more about the capabilities of stud welding beyond manufacturing high-quality electrical enclosures, contact Northland Fastening Systems at (651) 730-7770 or request a quote online.

Breaking Down the Process of Quality CD Stud Welding

Posted on by norfas by norfas

Northland Fastening Systems provides high-quality stud welding services, stud welding tools for sale and rent, and every stud welding accessory you need to get the job done. From food-grade welding to structure-strength sheet metal welding using both drawn arc and capacitor discharge (CD) welding, NFS has the right equipment for the job.

 

Because stud welding is such an efficient, effective, and powerful tool in a wide range of industries, it’s one of the most critical operations in many fabrication projects. Both drawn arc stud welding and CD stud welding have a foundational use in different types of welding projects, but more and more technicians are utilizing state-of-the-art CD welding units for rapid welding purposes.

 

CD stud welding is, for all intents and purposes, a form of arc welding. In comparison to drawn arc stud welding, however, it’s much faster, performing a pre-calibrated weld in milliseconds that leaves little-to-no mark on the opposite side of the weld surface.

 

CD Stud Welding Step by Step

With the right tools, performing CD stud welding is a straightforward process for welders of all skill levels. Most CD welding units offer pre-programmed settings for a weld cycle, or simplistic ways of calibrating a preset voltage depending on the stud materials and size as well as the material of the weld surface. The process goes as follows:

 

  1. The stud welding unit is calibrated to suit the situation.
  2. A stud is loaded onto the gun tip.
  3. The stud welding gun is positioned at the desired weld point.
  4. The welding operation is triggered, sending energy stored in the capacitors to be discharged onto the stud in a semi-automatic arc.
  5. The heat of this energy essentially vaporizes the tip of the stud and creates an ionization path.
  6. The path opens up a full flow of current arcing across the stud and melting the metal of the stud tip.
  7. Pressure from the welder then forces the molten tip of the stud onto the weld surface.
  8. This pressure and the cooling metal forms a strong bond between the stud and the weld surface.

 

CD stud welding doesn’t use a ferrule like its cousin, drawn arc stud welding. This means the weld is performed much more quickly, but the nature of the weld limits the size of the stud. CD welding is suited to stud diameters from 14 gauge up to 3/8”, there are no limitations on stud length. Materials that can be welded using CD stud units include stainless steel, mild steel, brass, and aluminum. Although CD stud welding is not the best choice for heavy-duty purposes, it has a prevalent use in smaller scale, rapid, efficient production. Its weld connection is stronger than the stud material itself, and it can be more easily automated than other types of welding.

 

To learn more about CD stud welding  and the services or products we provide that are fitted to that operation or others, contact Northland Fastening Systems at (651) 730-7770 or request a quote today.