Author: norfas

Advantages of Automated Welding Equipment on a Downstream Production Line

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For fastening sheet metal and other steel parts, no better choice can be made than stud welding. Stud welding operations can quickly install studs in a wide range of diameters and lengths, resulting in connection points stronger than the stud and base material put together. Stud welding also only requires access to one side of a work surface and does not require cutting a hole. Compared to other fastening systems, stud welding is leak proof, making it more resistant to corrosion, and offers a sleeker appearance. In addition to these factors, stud welding has many advantages over other fastening systems, whether it’s used by a welding technician to manually install studs or on an automated downstream production floor. For both manual work and automated applications, Northland Fastening Systems (NFS) has a complete supply of welding equipment, from tools and studs to efficient automation technology.

Welding Equipment

Any downstream production line that already utilizes stud welding or a comparable fastening system that could easily be replaced by studs will find multiple benefits with an automated system. This is especially true for fabricators working with sheet metal and steel parts.

Advantages of Welding Equipment

Some of the many advantages that automated stud welding equipment could offer your production line include:

  • Energy efficiency: Automated systems are programmable to exact tolerances so they can work within the lowest energy parameters possible. Our automated equipment can reduce industrial energy consumption, saving you money and lowering your facility’s carbon footprint.
  • Speed: With a programmable automated system, you will see increased production speeds in two ways. First, because it is controlled to exact degrees, the automated equipment itself will move over a part quickly, some as fast as 60 meters per minute. Second, stud welding operations can be completed as rapidly as 0.01 seconds, making them one of the fastest connector techniques.
  • Reliability: With an automated system, stud welding results have an accuracy of around ± 0.15 mm for steel and ± 0.2 mm for aluminum in most cases. This makes it the most reliable system you can integrate into your production line for fastening techniques.
  • Low maintenance: Most stud welders require little to no rigorous maintenance. Even automated systems that routinely install hundreds of studs only need minimal upkeep. High-quality automated designs will save you time and money, thanks to their low demand for maintenance.
  • Safety: One of the biggest advantages to incorporating an automated system on your downstream production line is worker safety. With a completely self-sufficient operating system running on a controllable software program, workers avoid injury, fatigue, and other risks on the job.

Summary

These are just a few of the many benefits you’ll see when you integrate an automated stud welding system into your production line. To learn more about the automated welding equipment and other tools, studs, and accessories we provide, contact NFS at (651) 730-7770 or request a quote online.

Applications and Benefits of Structural Steel Welding

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Skyscrapers and other multistory buildings are known for their use of powerful steel beams, like the one showcased in the famous Lunch Atop a Skyscraper photograph. While these large buildings rely on structural steel for their construction, those materials are also used in many different industries. From general manufacturing to the aerospace industry, structural steel is often included in the products themselves or in the machinery that gets the job done. For several applications that use steel beams, stud welding is a critical fastening system that provides strong, clean connection points quickly and efficiently. Shear connectors, bar anchors, and several other stud types are significant supplies for composite building with steel beams, but there are other types of structural steel welding that utilize stud welding equipment. If you’re stud welding structural steel, you can find everything you need with Northland Fastening Systems (NFS). NFS has a comprehensive supply of welding tools for rent and purchase, studs, accessories, and more.

Structural Steel Welding

Welding with studs like shear connectors and bar anchors is an often-overlooked part of what makes constructing and manufacturing with beams and other structural steel possible. While the primary use of steel is in the construction industry, the material and stud welding systems are also used in the shipbuilding, automotive, mining, aerospace, energy, and manufacturing industries.

Structural Steel Welding is a Large Part of Global Infrastructure.

Because structural steel is used so heavily throughout industries, it’s a large part of global infrastructure. Aside from buildings, studs make up a large part of composite construction, allowing for the building of bridges, roads, pipelines, and mines.

Stud welding is the best fastening system in existence for steel and composite construction. Not only is it cost-effective and fast, but it also creates a bond stronger than the stud itself. Stud welding has a better appearance than most other attachment techniques, leaving the reserve weld surface mark-free.

Major benefits

Other major benefits of stud welding with steel include the fact that workers only need access to one side of the work surface and that a stud-welded connection is leak-proof and resistant to corrosion. Alternative fastening systems like rivets require access to two sides of a surface, and rivets have a tendency to fail or loosen over time. Studs will not require replacement when the weld is performed correctly and is operating within expected parameters.

Stud welding units like the Tru-Weld TW 6902 and many others on the market are perfect for job sites where structural steel construction takes place. They are portable and robust for easy transportation, and they are also extremely easy for operators to learn and operate.

Overall, when building with structural steel and composite construction, stud welding should be your choice for fastening systems. For more information about supplies for structural steel welding, contact NFS at (651) 730-7770 or request a quote online.

 

 

 

 

Part 2: Attaching Welding Studs to Advanced High-Strength Steel Automotive Surfaces

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Part 1 of this two-part blog series covers the development of advanced high-strength steel (AHSS), also known as automotive steel, and the first-generation AHSS categories, which includes a brief description of first-generation ferrite and martensite-based steels such as DP, MS, CP, and TRIP steels. In Part 2, we  cover second-generation steels and the use of AHSS in the automotive industry. Since the beginning of AHSS development in the 1990s, these materials have slowly begun to replace various steel and aluminum components in multiple vehicles. In many instances, AHSS offers a higher crash resistance than aluminum and is lighter than other steels, making vehicles both safer and more efficient. As with aluminum and any other steel parts, many AHSS components of modern vehicles are constructed with stud weld fastening systems. Stud welding is a mainstay in automotive manufacturing. Not only does it provide a powerful, clean connection point that can be quickly installed, it’s also cost-effective, leak-proof, and only requires access to one side of a work surface. At Northland Fastening Systems (NFS), we work with multiple customers in the automotive industry to supply welding studs, accessories, and other equipment.

Welding Studs

Fastening welding studs to AHSS surfaces requires an understanding of the correct stud materials and dimensions, as well as tool and power calibration, but it can easily be done. Many manufacturers working with AHSS have quickly transitioned their stud welding technicians to these newer materials.

AHSS Material

The second generation of AHSS materials are based on austenitic microstructures. Current second-generation high-strength steels include:

  • TWIP steel: Twinning-induced plasticity (TWIP) steel has excellent mechanical properties at room temperatures. It is highly resistant to corrosion with outstanding strength and energy absorption greater than twice the ability of previously used steels.
  • L-IP steel: Lightweight with induced plasticity (L-IP) steel is a lighter version of other TWIP steels. They are high-manganese alloys that have high-impact resistance and stretch, forming properties ideal for automotive parts.
  • SIP steel: Shear band formation-induced plasticity (SIP) steel is another material based on TWIP alloys. When shear band force is applied to SIP steel, structures are actually strengthened in the austenitic matrix.

AHSS in Welding Studs

Both first- and second- generation AHSS types are utilized in the manufacturing of vehicles ranging from daily drivers to public transportation. Not only are these steels stronger than conventional steels and aluminum, they are also lighter, more sustainable, and even more affordable than previously used materials. These steels are utilized in modern vehicle parts that will absorb shear force, high-energy resonance, shock, load bearing, and many other critical components.

If you’re working with AHSS in the automotive industry, or any other application such as aircraft, shipbuilding, or general manufacturing, stud welding is likely one of your primary fastening systems. For more information about our supply of welding studs and other equipment, contact NFS at (651) 730-7770 or request a quote online.

Part 1: Attaching Welding Studs to Advanced High-Strength Steel Automotive Surfaces

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The earliest forms of welding, dating as far back as 1,800 BCE, forged basic bronze and irons into various weapons and tools. Over the centuries, more sophisticated uses of metal developed, such as the pattern welding used to make Damascus steel and Japanese swords. When electricity was harnessed in the 1800s, resistance-welding technology was quick to advance. Today, we have many resistance-welding techniques and other arc-welding operations that utilize electricity to heat metals. Stud welding is one of many modern operations that use specifically calibrated electrical currents to fuse metals. While it’s implemented extensively throughout multiple industries, stud welding is also a frequently used fastening technique in the automotive industry. In the past 10 years, car companies have replaced a large number of other steel and aluminum stud welded parts with advanced high-strength steel (AHSS) due to its weight and crash resistance. If you’re working with AHSS and welding studs, you can find all the supplies and technical support you need with Northland Fastening Systems (NFS).

Welding Studs

NFS offers a complete supply of drawn arc and CD studs, welding tools for rent and purchase, accessories, and the advice of our own welding technicians. We also provide repair services for the majority of stud welding models.

Because one of the most prevalent uses of AHSS is for automotive parts, the different types of those materials are often discussed and classified as automotive steels with a minimum tensile strength of 440 MPa.

Welding Studs with AHSS Materials

There are two generations of AHSS materials. The first generation of AHSS includes ferrite and martensite-based steels, while the second-generation group are steels based on austenitic microstructures. Attaching welding studs of any dimensions to an AHSS work surface requires an understanding of the steel itself.

  • DP Steel: Dual-phase (DP) steel is a first-generation ferrite-based steel category. DP’s high-strength steel grades have low-yield strength to tensile strength ratios, high-fatigue resistance, and uniform elongation properties.
  • MS Steel: Martensitic (MS) steel is a first-generation stainless steel alloy. It can be tempered and hardened with heat treatments to become highly durable, wear-resistant, and strong in mechanical applications.
  • CP Steel: Complex-phase (CP) steels are extremely fine-grained with micro ferrite structures. They have high work-hardening properties, high-fatigue strengths, wear-resistance, and can absorb high energy resonance.
  • TRIP steel: Similar to CP steel, transformation-induced plasticity (TRIP) steel has a high-yield strength for first-generation steels. Their microstructures of austenite can be transformed to martensite structures when bearing load or being deformed.

Summary

In the second part of this two-part blog, we discuss second-generation AHSS steels and all AHSS applications in the automotive industry. If you’re working with welding studs on an AHSS work surface or any other materials, you can find the supplies you need with NFS. Contact NFS at (651) 730-7770 or request a quote online.

 

 

 

 

 

Advantages of Stud Welding over Other Fastening Systems

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Throughout manufacturing history, many methods of fastening one component to another have been implemented, ranging from the most rudimentary nails to the most advanced industrial adhesives. The best fastening systems in any given situation depend on several factors, such as materials, dimensions, function, and finish. When it comes to fastening steel, aluminum, copper, bronze, and many other metal components, stud welding is often the superior choice. When properly applied, welded studs have a connection point that is quickly applied, mark-free, and powerful. In addition to stud welding’s use for metal fasteners, it’s also a key part of composite construction for steel and concrete builds. Northland Fastening Systems (NFS) is a supplier of all the necessary tools, studs, and accessories for drawn arc, CD, and short cycle stud welding operations. We offer customers a complete selection of welding materials and equipment, including our own technicians’ expert advice and guidance.

Fastening Systems

While stud welding is just one of many fastening systems for multiple applications, there are several ways it outperforms other techniques and provides greater advantages in comparison. Some of the most common fastening techniques that stud welding outperforms include:

  • Bolting: Conventional bolting is a frequently used fastener because it’s highly accessible and generally cost effective. In comparison, stud welding installation costs are actually lower and faster. Two-sided access is not required to install studs, and they can be installed without a visible head. Stud welding is also resistant to leaks and vibration, and does not require through-hole preparations.
  • Boring, drilling, and tapping: Stud welding is a faster process than any boring, drilling, and tapping operations. It has a lower install cost, does not require through-hole preparation, and has better resistance to resonance and leakage. Most important, stud welding doesn’t leave marks on the reverse side of the installation surface.

More Uses

  • Soldering: Unlike soldering, stud welding can be applied to painted surfaces and it generally calls for less training time. Stud welding is faster than soldering and has lower installation expenses.
  • Clinch fastening: Clinch fastening requires high-pressure application and two-sided access to the connection surface. Stud welding needs neither of these for a successful connection, and it doesn’t leave marks or a visible head. Stud welding requires no preparation for a through-hole, and it resists leaks and vibration. Also, clinch fastening equipment is not portable, whereas many stud welding units can be easily moved throughout a job site.

In almost every instance in which one of these common fasteners can be used, stud welding can replace it for faster, stronger, cheaper, and better-looking results. If you’re working with any of these fastening systems, consider replacing those operations with stud welding. For more information, contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.

Specialized Groups of Construction Equipment Built with Steel Weld Studs

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There are many tools and types of equipment we use daily that are built with stud welding processes. From the cars we drive to the appliances we use in our kitchens, stud welding operations are frequently called on for efficient, strong fasteners throughout various industries. The prevalence of stud welding being used for various fastening systems is due to its many benefits. Stud welding creates a powerful connection point with clean results. It can also be used in fastening multiple materials, including steel, aluminum, copper, and brass, and it’s reliable for composite construction to combine materials like concrete and wood to steel beams. If you’re working with steel weld studs on your production floor or job site, you can find everything you need to get your project completed at Northland Fastening Systems (NFS).

Steel Weld Studs

One major use of steel weld studs is in the manufacturing of construction equipment. Common construction equipment, such as excavators, cranes, dump trucks, and backhoes, are all built with steel studs, but many specialized types of equipment also rely on the use of stud welding in their fabrication.

  1. Dragline excavator: Used typically for excavation at greater depths, a dragline excavator has a long boom with digging buckets suspended from cables. These excavators are critical for the removal of sediment underwater. They are used in the construction of ports, marinas, canals, and for clearing pathways for water traffic.
  2. Trenchers: For pipe laying, cables, irrigation, drainage, and other systems, trenchers are used to dig long, deep ditches in the earth. They have a fixed arm with a digging chain or tooth-bladed digging wheels. Wheeled trenchers are best suited to cut through hard-packed earth and gravel.
  3. Pavers: In road construction, pavers are essential when applying asphalt. Pavers have feeding buckets that are loaded continuously with a dump truck as the paver evenly distributes asphalt on the roadway. They provide partial compression to the asphalt, but a roller must go over the surface as well for full compaction.

 More Uses

  1. Telehandlers: Telescoping handlers are hoisting machines that can lift heavy-duty materials or equipment up to construction scaffolding and platforms. They can also raise and lower workers to different job-site levels with buckets or cabins.
  2. Feller bunchers: In logging and site clearing, feller bunchers are large-scale grips that can hold trees, make a cut, and move large branches without the trees felling. Felling trees makes for a dangerous worksite, but a feller buncher helps quickly and efficiently remove trees and free up a site for dump trucks and excavators to enter.
  3. Piling equipment: Foundation construction requires the boring or driving of piles into the earth. Pile borers can drill holes into the ground, and hydraulic drivers ram the pile into the ground to the required depth.

For any of the preceding construction equipment, you can count on us to supply you with the correct steel weld studs and other materials. Contact NFS at (651) 730-7770 or you can request a quote online for more information.

 

 

Full Scope of Applications for the Stud Welding Process

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Compared to many other manufacturing operations, stud welding is a relatively young technology. The first uses of stud welding didn’t occur until after World War I in the early 1900s. Early stud welding was used in composite construction to fasten wood to steel beams in the shipbuilding industry. Today, stud welding is still used in shipbuilding, but it’s also heavily utilized across multiple industries for a vast range of applications. As a fastening system, stud welding creates powerful connections quickly without needing access to two sides of a work surface and without leaving marks on the reverse side of the weld. If you’re working with any kind of stud welding process you can find all the supplies you need with Northland Fastening Systems (NFS).

Stud Welding Supplies

NFS provides a complete supply of studs, welding tools, accessories, repair work, and the advice of our own expert technicians. The reach of the stud welding process across industries is broad, and we work with many customers to help them complete all kinds of projects.

Stud Welding Process

The full scope of stud welding as a manufacturing operation includes the following industries:

  • Automotive: For cars and other vehicles, stud welding is used to install heat shields, power steering components, electrical routing, insulation, exhaust components, instrumentation, trim, hydraulic system components, and more.
  • Infrastructure: Because the stud welding process can install shear connectors that combine steel to concrete, it can be used for large-scale infrastructure, such as roads, bridges, piping, conduits, drainage systems, and more.
  • Construction: Stud welding is often used to build multistory buildings, such as apartments, offices, municipal buildings, and even skyscrapers.
  • Agricultural equipment: Farming equipment relies on stud welding for the installation of many parts, including brackets, cabs, spreaders, threshers, fenders, hoses, shrouding, and more.
  • Appliances: Both large and small appliances are often built using the stud welding process. Commercial and residential dishwashers, refrigerators, washing machines, stoves, microwaves, ovens, and many other common appliances are built with studs.
  • Shipbuilding: Ships of all sizes are built with stud welding to this day.
  • Electronics: From hydraulic lines and transformers to terminals and enclosures, many electronics are built with studs.

More Industries

  • Industrial: Signs, cover plates, enclosures, controls, and floor indicators are some examples of industrial equipment made with stud welding.
  • Furniture: Many metal furniture items are made with studs, such as filing cabinets, shelving, racks, and desks.
  • Lawn and garden: Lawn mowers, seeders, tractors, and some other gardening and landscaping equipment are built with stud welding.
  • Power and energy: Transformers, tanks, transducers, and other energy equipment use studs as fasteners.
  • Cookware: Pots and pans, utensils, and other kitchen supplies are built with food-grade stud welding.
  • Jewelry: Pins and thin studs can be used for decorative purposes like jewelry.
  • Hardware: Tool handles, interior design hardware, brackets, and other systems can be installed with stud welding.
  • Doors: insulation doors, escutcheon plates for door knobs, and some commercial doors are installed with studs.

This is just a sampling of the many applications of stud welding. For more information about the uses of the stud welding process, contact NFS at (651) 730-7770 or you can request a quote online.

 

Tagging, Name Plating, Insulating, and Other Small Diameter CD Stud Welding

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Different types of stud welding operations each have its own range of applications in a broad scope of industries. Not only has drawn arc stud welding been used for shipbuilding since the early 1900s, it’s also used today for automotive production, bridge and other infrastructure construction, multi-story buildings, construction equipment, and many other manufacturing industries. CD stud welding has its own wealth of uses, from food grade equipment fabrication to the installation of insulation materials. No matter what type of stud welding you’re working with, you can find the supplies and support you need with Northland Fastening Systems (NFS).  NFS provides a comprehensive selection of studs, welding tools for rent or purchase, welding accessories, and even repair services for most welding models. Our team of expert technicians also offers guidance and support for any of your welding questions.

CD Stud Welding Operations

While many drawn arc and CD stud welding operations are used in heavy-duty to mid-size construction, there are also valuable small-scale applications that use studs and pins with diameters under ¼” wide.

Uses of CD Stud Welding

Some of the most prevalently used small-scale CD welding solutions include insulation, name plates, and other labeling systems.

  • Insulation pins: NFS offers 1″-long, 10-gauge diameter standard CD insulation weld pins made from mild steel. These pins are highly useful in quickly and effectively attaching insulation in a broad range of construction scenarios. Insulation for pipes, building interiors, HVAC ducts, industrial equipment, incinerators, and many other locations can be installed using CD welded insulation pins.
  • Name plate studs: Another CD welding application is the installation of name plates with breakaway studs. These studs are tipped with small domed pins that break away from the part inserted into the weld gun. Name plates on equipment that show models, serial numbers, and many other specifications are almost exclusively installed with these welding studs. They are also used in installing small signs and even for decorative purposes.
  • Tag welding: Not to be confused with TAG (Tungsten Active Gas) welding, tag welding is an effective labeling system for steel part inventories. Tags can be quickly installed on a bare steel part, such as beams, rebar, and billets, with a connecting CD stud. Tagging materials with CD studs can easily provide clear labels that won’t get lost or break off. The installation process takes seconds and is a cost-effective organization solution.

Summary

These three types of small-diameter CD stud welding are key to many production and construction operations. They offer a strong fastening system with quick, reliable operations. For more information about welding pins and studs, or any other supplies we stock, contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.

History of Sheet Metal and Arc Stud Welding

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While general welding dates back to the Bronze Age, the history of stud welding is much more recent. The first stud welding operations were developed in the early 1900s in the shipbuilding industry. Those early operations were rudimentary compared to the capabilities of stud welding today. Modern stud welding can be done manually on a jobsite or in an automated capacity in the manufacturing facility. Either way a weld is performed, when done correctly, it will generate a connection point that is clean and stronger than both the stud and surface material. Stud welding is used across industries from the automotive sector to food service supplies. Whatever kind of project you’re working on, you can find all the stud welding supplies you need with Northland Fastening Systems (NFS). NFS has a complete supply of materials for capacitor discharge (CD), short cycle, and drawn arc stud welding, including studs, tools, accessories, and even repairs.

ARC Stud Welding

One of the main reasons why arc stud welding and other stud welding operations are used so prevalently across industries is because of their compatibility with sheet metal and the fasteners used to build with those materials.

Arc Stud Welding Uses

Sheet metal has its own large range of specifications, such as thickness, material type, manufacturing technique, and surface treatments. Even with this range, however, stud welding is often a useful operation for attaching sheeting to other structures, fixing studs and other fasteners to sheeting surfaces, and thru-deck welding to connect sheeting to steel beams.

Uses for Sheet Metal

Humans have used sheets of metal for centuries. The oldest metal sheets were hand-hammered and used for both decorative and functional purposes. The first idea for a rolling mill is credited to Leonardo da Vinci from a sketch drawn c. 1485, but the first recorded accounts of water-powered sheet-rolling mills didn’t occur until the early 1500s. Check out the following timeline:

  1. 1485: Leonardo da Vinci makes several sketches detailing his idea for a rolling mill.
  2. Early 1500s: Some records show two rolling mill designs that were used to make gold sheeting for coins.
  3. 1600s: The use of a puddling technique for sheet metal was used. This method is somewhat effective, but often loses over half of the iron content into the sand bed while the metal is molten. The puddling method was used to make metal sheets that are part of the Eiffel Tower and the Statue of Liberty.
  4. Late 1600s: The first tests of rolling iron to make tinplate occurred around 1670. Ironmaster Major John Hanbury built rolling mills for tinplate and black plate.
  5. Late 1700s and the Industrial Revolution: The beginning of modern sheet metal manufacturing began during the industrial revolution. The first iron casting techniques were developed in the early 1700s. By the time of the industrial revolution at the end of the 18th century, rolling and casting sheet metal processes began to be perfected.

Summary

Today, many applications of arc stud welding and sheet metal are used across the manufacturing world. To learn more about the stud welding supplies we provide, contact NFS at (651) 730-7770 or request a quote online.

 

 

 

Our Market Today for Industrial and Construction Welding

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Northland Fastening Systems started in 1987 with the goal of bringing stud welding into the future and committing to excellence in service and products. Over the past 30 years, we’ve seen many changes in the stud welding industry, from new products and technologies to differences in the market itself. Today, stud welding is used across industries, including the construction of buildings and infrastructure, installing insulation, building electronics, and much more. In many ways, stud welding is a superior fastening system. Stud welding quickly provides a powerful, clean connection point, requires access to only one side of a work surface, is leak and corrosion resistant, and is cost-effective. For any manufacturers and contractors working with stud welding, Northland Fastening Systems has the supplies and services needed to get the job done. We provide a comprehensive supply of studs, accessories, tools, and other support for industrial and construction welding.

Construction Welding

In our past 30 plus years of operation, the biggest market change we’ve seen is the shift in demand for construction vs. industrial stud welding supplies. In the early days of NFS, many parts of the Twin Cities were still being built to become the metropolises they are today. The greatest demand for supplies came from the construction welding industry.

Now that metro area growth has slowed, a large increase in industrial demand has grown, shifting the majority of our market supply from construction to industrial.

80% Industrial

Today, about 80% of our business is with the industrial market. This includes customers manufacturing parts and assemblies of all kinds. We supply to the automotive, electronics, food service, sheet metal, agricultural equipment, robotics, and even furniture industries. The largest use of industrial stud welding supplies includes electrical enclosures and enclosures in general, commercial and industrial food service equipment, and the fabrication of multiple parts with sheet metal. Factory equipment is also largely built with studs and other types of industrial welding systems.

20% Construction

While demand for construction welding supplies has decreased, the construction market still makes up about 20% of our business. Many different types of multi-story buildings and other structures are built with stud welding. The use of shear connectors in composite construction is critical for bridges and other infrastructure, and thru-deck welding is a prevalent operation in modern building. In addition to thru-deck welding and shear connectors that fasten concrete to steel beams, bar anchors are also used in composite construction, and CD studs are key in the installation of insulation for most building types.

Stud welding continues to be one of the most versatile and reliable fastening systems today for both the industrial and construction markets. For more information about our supplies for industrial and construction welding, contact Northland Fastening Systems today at (651) 730-7770 or request a quote online.