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Selecting Ferrules to Pair with Your Stud Welding Products

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Three main kinds of stud welding operations are utilized in a range of industries. Capacitor discharge (CD) welding is useful for rapid, clean operations with thinner diameter studs and pins. Common applications of CD stud welding include insulation installment, electrical enclosures, and food service equipment. Another operation, drawn arc stud welding, can be used for larger diameter fasteners. Drawn arc studs are used in heavy-duty construction projects like bridges, roadways, and multistory buildings. Short cycle welding is the third type of stud welding operation used across industries. Essentially a drawn arc process, short cycle welding can be automated more easily, performed faster, and done on uneven or coated surfaces. No matter what kind of welding operations you use, you can find all the stud welding products you need at Northland Fastening Systems (NFS). We supply a comprehensive range of welding tools for rent or purchase, drawn arc and CD welding studs, welding accessories, repairs for most models, and the expert advice of our own technicians.

Ceramic Ferrule

In most cases, drawn arc stud welding will utilize a ceramic ferrule placed at the point of the weld. Ferrules help control the weld by containing molten metal and providing some temperature regulations. However, because drawn arc welding can be done on many kinds of surfaces—including at various angles, for different profiles, and with a broad range of dimensions—there is an equally diverse selection of ferrules you can choose from. Picking the right ferrule depends on the conditions of your weld.

 Stud Welding Products

There are 10 standard ceramic ferrule stud welding products you can choose from, including:

  1.  Flat and flat heavy-duty: These ferrules are used with down-hand operations and can be paired with headed studs, deformed bars, fully threaded studs, and in vertical applications with studs under ⅜” diameter.
  2. Collar: These are used with collar studs, studs with short applications, or low-profile studs.
  3. Reduced base: Studs with reduced bases, such as ones with unthreaded sections at the tip, work best with reduced base ferrules.
  4. Pitch: These are used with partially threaded studs to accommodate the pitch in diameter from the wider threaded portion to the slimmer unthreaded portion.
  5. Thru-deck: Thru-deck welding is a common construction operation, and it requires thru-deck ferrules. These are most useful in composite construction with steel and concrete.
  6. Thru-deck wired: Similar to thru-deck ferrules, these are used with ¾” stud diameters that can be installed in rapid operations.
  7. Angle: When studs need to be installed at an angle, these ferrules can be utilized with inside or outside angle positioning.
  8. Vertical: Studs can be installed on vertical surfaces, but the operation needs to use a vertical ferrule to contain the molten metal and prevent drips.
  9. Flat heavy-duty special: Special ferrules have finer teeth at their base, which helps with ½” vertical applications and the installation of deformed bar anchors.

To learn more about ferrules and other stud welding products, contact NFS at (651) 730-7770 or request a quote online.

Tallest Buildings in the World Made Possible with the Stud Welding Process

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Stud welding is a versatile manufacturing operation that can be utilized for a broad range of fastening systems. Because of the many uses of stud welding, various stud weld operations are used throughout industries. From automotive to medical industries, many manufacturers rely on stud welding for safe, long-lasting connections. Another important function stud welding provides is in composite construction for infrastructure and large-scale building. If you are using the stud welding process for any kind of composite construction or other structural building, Northland Fastening Systems (NFS) has the supplies, tools, and technical support you need. We provide a comprehensive selection of drawn arc and capacitor discharge (CD) studs, welding tools for rent or purchase, welding accessories, and repair services for a range of welding models.

Stud welding process using composite construction:

Composite construction is a key part of building with materials like concrete and steel, both of which are significant factors of road and bridge infrastructure, multistory buildings, and other large-scale constructions. In fact, without the stud welding process, some of the world’s tallest buildings today wouldn’t be possible.

Tallest buildings made with the stud welding process:

Burj Khalifa:

Built in 2010 in Dubai, the Burj Khalifa still holds the title of tallest in the world. It reaches 2,717 feet with 163 floors and one additional floor below ground. The Burj Khalifa is built in a neo-futuristic style and relies on a structural skeleton of reinforced concrete, steel, and aluminum.

Merdeka 118:

One of the newest of the world’s tall buildings, the Merdeka 118 was completed in 2022 in the capital city of Malaysia. The Merdeka (meaning “independence” in Indonesian) Tower is a combination of neo-futuristic style and a Malay traditional songket pattern. The tower stands 2,227 feet with 118 floors and five others below ground.

Shanghai Tower:

Until the construction of the Merdeka 118 tower, the Shanghai Tower held the title of second tallest. It was built in Shanghai in 2015 and stands 2,073 feet tall. It has 128 floors, with five additional floors below ground.

Abraj Al-Bait Clock Tower:

Constructed in 2012 in Mecca, Saudi Arabia, the Abraj Al-Bait Clock Tower stands 1,972 feet tall. It has 120 floors, with three others below ground. The tower is built in a postmodern, neo-classical style, featuring an ornate (and enormous) atomic clock and golden spire.

Ping An International Finance Center:

The Ping An tower was constructed in 2017 in Shenzhen, China. It stands 1,966 feet (to its tip) and has 115 floors, with five additional below ground. It currently has the world’s highest observation deck at 1,844 feet.

Composite construction using stud welding process:

These are just some of the hundreds of super tall buildings in the world built with composite construction using steel and concrete. The stud welding process makes it possible to form powerful connections and shear force absorbers with those materials to construct taller and taller buildings.

To learn more about our stud welding supplies, contact NFS at (651) 730-7770 or request a quote online.

 

Sheet Metal Fabrication for Construction Welding with Studs

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Metal working and, in particular, constructing tools and equipment with metals is a practice dating back to the Bronze and Iron Ages. The Bronze Age began in about 3300 BCE and led into the Iron Age around 1200 BCE. Over thousands of years, our understanding of metals and the application of different metal objects expanded greatly. Even in the last 50 years, scientific research and development of high-performance metal alloys has advanced significantly, including improvements to sheet metal. Today, many industries are reliant on sheet metal for the fabrication of countless tools and equipment. Some of our largest global industries completely rely on the production of high-quality, specialized sheet metals for manufacturing. For example, the automotive, aerospace, railroad, oil, electronics, food, medical, computer, military, agricultural, and construction industries would be unable to operate without access to sheet metals. Within the majority of those industries, construction welding is used to apply studs and build with sheet metals for strong, clean fastening systems. At Northland Fastening Systems (NFS), one of the main industries we supply with studs, tools, accessories, and other equipment is the sheet metal welding industry.

Studs Attached With Construction Welding

Structural steel building with sheet metals includes several steps on the production line, including cutting, bending, assembling, and more. Stud welding fasteners are an important part of the fabrication process. Studs attached with construction welding have a strong bond to sheet metal surfaces; they offer a clean, mark-free finish, and they are an affordable, efficient fastener option.

Grades of Sheet Metal

Stud welding can be used in all kinds of applications with any grade of sheet metal. While there are many kinds of sheet metals available today three main categories of all sheeting still remain: commercial, industrial, and structural.

  1. Commercial metal sheeting is used to build a wide range of products marketed to individual consumers and businesses. Common examples of products made with commercial metal sheeting include appliances, electronics, and cars. Commercial metal sheeting is so prevalent across industries that almost every household and business will use a product made with stud welding sheeting daily.
  2. Industrial metal sheeting is used to manufacture parts that can be integrated into other products down the line. Manufacturers are the main purchasers of industrial sheeting, and they typically use that material to make parts for tools like bandsaws, drill presses, hydraulic systems, and more.
  3. Structural steel sheeting is used in the construction welding industry. Sheeting installed in buildings and infrastructure like skyscrapers, bridges, water towers, shops, factories, and even homes are all structural metals. Stud welding is used throughout many construction welding processes.

For more information on our supplies and how we support sheet metal fabrication industries, contact NFS at (651) 730-7770 or request a quote online.

The Great Range of Stud Welding Process Applications

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Stud welding is one of the most valuable operations as a fastening system for the manufacturing and industrial world. Various types of stud welding have hundreds of applications, from large-scale infrastructure to tiny insulation pins. The stud welding process is versatile, quick, and when performed correctly, provides a powerful connection point with greater benefits than other fastening systems. Stud welding operations began in the early 1900s in the shipbuilding industry, but since then, have spread to many other applications and sectors of industry. No matter what you’re utilizing stud welding for, Northland Fastening Systems (NFS) can help you get the job done with our comprehensive selection of tools, studs, and other supplies. We provide tools for rent or purchase, studs in a broad range of dimensions with custom options available, stud welding accessories, repairs of most tool models, and the expert support of our own welding technicians.

Stud Welding Process

The three types of stud welding—drawn arc, capacitor discharge (CD), and short cycle— each has its own range of applications throughout different industries. Drawn arc welding is typically used in “heavy duty” applications like shear connectors in composite construction and headed anchor studs in concrete embedments. CD and short cycle welding are often used for rapid, lightweight connection points with smaller diameter studs and pins, such as the installment of insulation.

Three Types of the Stud Welding Process

All three types of stud welding have important uses that fall into the great range of stud welding applications, including the following.

Construction:

Composite construction with concrete and steel, beams, sewage and plumbing system pipes, roads, bridges, and many other applications use stud welding as a fastening system. Strength, flexibility, and other properties of studs make these construction techniques possible.

Automotive:

Stud welding is highly prevalent throughout the automotive industry. Cars, trucks, and other vehicles rely on the precision and strength of welding studs for fastening sheet metals, exhaust systems, heat shields, insulation, power steering, electrical wiring, and more.

Food:

In the restaurant, catering, food processing, packaging, and even home kitchen appliance industries, stud welding is a critical tool for building food-safe equipment. Hygiene and sanitation are the most important features of food production equipment, and stud welding allows systems to be built with the least risk of contamination.

Shipbuilding:

Stud welding is still important in its root industry. Stud application was largely relied on for building naval and freight ships during wartime throughout the 20th century, but today stud welding is used on all kinds of vessels, from battleships and submarines to small motor boats and yachts.

There are many other industries that utilize stud welding operations. Manufacturers fabricating heating, ventilation, and air conditioning (HVAC) systems; furniture; agricultural equipment; electronics; signs; and even decorative items all use various forms of stud welding.

To learn more about the stud welding process and our supplies, contact NFS at (651) 730-7770 or request a quote online.

 

 

Using Construction Welding to Retrofit Older Buildings for Sustainability

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As the construction industry starts to implement more environmentally friendly, sustainable systems with longer lasting, high-quality materials, all new buildings are becoming some of the greenest we’ve ever seen. Even large industrial complexes and city centers are built with low-impact carbon emissions and sustainable energy in mind. While these new constructions are better than ever in terms of how they affect the earth, there are still many older buildings in use that could be improved with more sustainable retrofits and modernization. Around 50% of commercial buildings in the United States alone were built more than 50 years ago. There are many ways these older buildings can be improved for a lower carbon footprint by adjusting the existing structure without necessarily changing the historical significance. At Northland Fastening Systems (NFS), we know that stud welding and construction welding, in general, can be a large part of that retrofitting process.

Composite Construction Welding

There are many steps in the building process that rely on stud welding operations for quality construction. Stud welding is used in composite construction for attaching beams, girders, and other skeleton components to other important materials like concrete. It’s also used to fasten insulation sheeting to enclosed walls, build scaffolding needed in the construction process, create protected electrical systems, and more.

Construction Welding

The process of modernizing older buildings for sustainability with the use of construction welding takes several steps. Some of the most important steps include updating the following building components:

Electrical:

How a building generates electricity can affect how much energy is utilized on a daily basis. Retrofitting an electrical system can seriously change how energy is spent. Better power blueprints, longer lasting lighting, energy storage, and more can improve building sustainability. Electrical enclosures in buildings are almost exclusively built with capacity discharge (CD) stud welding operations.

Insultation:

CD stud welding is also used to install insulation pins quickly and effectively. Most older buildings have poorly installed, outdated insulation that doesn’t hold up to modern building conditioning. With the installation of better insulation sheeting throughout an older building, energy spent on maintaining well-conditioned indoor temperatures will drop almost immediately.

Heating, ventilation, and air conditioning (HVAC):

Another part of conditioning an older building that could be updated for better sustainability is the HVAC system, which can be a huge energy cost, especially for larger buildings that are not well designed or insulated with eco-conscious goals. If older buildings receive better HVAC systems (often installed with stud welding) with new motors, cooling agents, boilers, and filters, then emissions are greatly reduced in that area and the air quality will also likely improve.

Other adjustments can be made to the building’s main structure, roof, and even foundation for better sustainability, but the three areas discussed are the quickest and least invasive retrofit options for old buildings. To learn more about how stud welding and construction welding is involved in this process, contact NFS at (651) 730-7770 or request a quote online.

More About the Short Cycle Stud Welding Process

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Within the stud welding world, technicians can utilize several different types of operations, depending on materials and other specifications. While stud welding is one of the older branches of electrical welding, dating back as far as the early 1900s in the shipbuilding industry, the operations and technology have developed greatly beyond their original purposes. Today, welders can use drawn arc, capacitor discharge (CD), and short-cycle welding for anything from composite construction to electrical enclosures. The supplies required for stud welding can be equally wide-ranging in dimensions, materials, and function. No matter what kind of stud welding process you’re using or how big or small your project, Northland Fastening Systems (NFS) provides a comprehensive range of tools for rent or purchase, studs, welding accessories, repairs, and technical guidance.

Stud Welding Process

The short-cycle stud welding process can sometimes be considered a combination of drawn arc operations and CD studs. While this is partially true, short-cycle welding as a complete operation is much more complex and multifaceted than simply that.

Short-cycle Operation

The welding sequence of a short-cycle operation follows the same pattern as drawn arc welding, but it uses higher currents and shorter welding times (about 10-100 milliseconds). Overall, short-cycle welding is also best suited for installing studs with no greater than ½″ diameters on thin metal sheets. Most welding technicians will use shielding gas to improve the weld result of a short cycle process.

Useful for Installing Studs

Compared to drawn arc or CD operations, short-cycle welding is useful for installing studs that are not in a vertical position. Due to the quick weld time, molten metal at the weld point doesn’t have time for gravity to create drips and runs. With the fast weld, technicians don’t need to use ceramic ferrules, and in controlled environments they may even be able to eliminate shielding gas requirements.

Dimensions best suited to a short-cycle weld operation range from 1.7mm to 2mm for welding surfaces and thinnest CD studs to ½″ drawn arc studs. Three phase power supplies of 415 volts are recommended. Keep in mind how extension cables may affect your power.

Short-cycle welding can have risks of porous connection points if not performed correctly and with the right stud dimensions and welding surface materials. When done correctly, short-cycle stud welding has lower equipment costs, can be done with greater tolerances, and can even be worked into automated systems. For the right application, short-cycle welding is a convenient process that requires fewer accessories and additional tools than CD or drawn arc operations.

To learn more about the benefits of any stud welding process or for our supplies, contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.

Comparing Different Fixing and Fastening Systems with Stud Welding

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From tools as simple as a nail and hammer to as complex as an industrial-grade adhesive, many parts attach systems together. The right attachment method depends on the materials used, function of the assembly, operational stress, and aesthetic finish. When it comes to attaching metals together or to other materials, several techniques are available to manufacturers. One common application of metal fastening systems is welding. Different kinds of welding have been around for thousands of years, with rudimentary forge welding dating back to the Iron Age around 1200 BCE. Today, there are four main types of welding with multiple subtypes in those categories. Stud welding is one type of welding operation that was developed in the early 1900s for the shipbuilding industry. If you are working with stud welding, Northland Fastening Systems (NFS) has a comprehensive supply of studs and welding accessories as well as tools for rent or purchase, and our repair services to help you get the job done.

Fastening Systems

Unlike the commonly used tungsten inert gas (TIG), metal inert gas (MIG), and stick welding, which are used to connect metals along a linear path, stud welding operations are unique formats that connect metals at a point. As far as fastening systems go for attaching metals, we consider stud welding to be the superior operation for a variety of reasons.

For a full picture of why we like stud welding better than other operations that could be used in its place, we’ll take a look at those options.

Drilling and tapping:

This combo operation creates an insert for a fastener that can then be drilled into the surface material and secured with a bolt. While effective in many cases, drilling and tapping is a slow process. It also requires a lengthier stud, and can only be used in cases when the parent material is thick and doesn’t have a backside.

Inserts:

To install a metal backed insert, the parent material needs to be punched and deburred, which can weaken it. Inserts can also work loose over time, and they tend to crack paint and stain surfaces. Additionally, the backside of the parent material can be bent outward or otherwise warped.

Back welding:

Back welding installs fasters by welding on the reverse side of the parent material while the stud is held in place. This significantly alters the backside of a surface unless the excess weld is ground down. This entire process is slow and weakens the parent material.

Through bolting:

Through bolting is effective, but requires access to the backside of the parent material for two-handed installation. Bolt heads can also stain surfaces, weaken the parent material, and create an unsealed leak point.

Welding as a fastening Systems

Consequently, stud welding is the best system because it’s a strong connector, it doesn’t weaken the parent material, it can be done in a single step, it leaves a mark-free reverse side, and it’s a fully sealed connection point.

For more information about stud weld fastening systems contact NFS at (651) 730-7770 or request a quote online.

 

Human vs. Robot: How to Choose Your Stud Welding Equipment

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In most industries today, manufacturers have a range of technician-operated and automated tools and equipment they can utilize for production. In most cases, a facility will have a combination of hand-operated and CNC or robotic fabrication tools. Even fully-automated production lines, however, require human interaction at some point in the process. Stud welding is a versatile manufacturing operation that has both automated and handheld operations. Because there are benefits to both kinds of operations, it’s important to understand the best applications for each before purchasing equipment, establishing a fabrication setting, training employees, or investing in additional welding materials. Whether you’re working with technician-operated handheld tools or fully automated production systems, Northland Fastening Systems has the supplies you need. We provide a complete selection of stud welding equipment, including tools for rent or purchase, welding studs, accessories, and more. Our own welding technicians also offer expert advice for fabricators working on all kinds of projects, and we service and repair most welding tool models.

Stud Welding

Stud welding as an operation in general is versatile and offers simple, yet powerful, solutions to fastening and composite building. When it comes to choosing automated or manual stud welding equipment, consider the application, materials, welding process, location, and volume of your targeted production.

Handheld (manual) models:

Most welders are trained to use handheld welding guns for drawn arc and capacitor discharge (CD) operations. The main benefits of a handheld model are the flexibility and portability of the tool. Handheld welders can be easily transported from place to place for onsite welding, and it’s relatively easy to train new operators on manual tools. Manual welding tools are also usually cheaper than full production systems, and they can often be calibrated quickly to accommodate studs in various dimensions, different welding materials, and the type of stud.

Robotic (automated) welding:

If you have the facilities for production welding systems and require rapid, large-scale welding with significant repetition, you may want to consider different automated welding setups. Production welding technologies are highly advanced for the manufacturing process. They are built to be fully programmable and handle automatic feeds of studs and welding surfaces quickly. Using an automated welding system also reduces the risk of operator injury and fatigue with heavy duty, rapid load jobs. Most automated welders can perform 40 to 60 stud welds a minute or more with integration into a production line.

Stud Welding Equipment

Both automated and manual stud welding equipment offer precise, strong connection points for fasteners and composite construction. Either option also gives you variety in the materials, dimensions, and additional specifications. For more information about both types of welders, contact Northland Fastening Systems at (651) 730-7770. Request a quote online to get started with us today.

Stud Welding Products Affected by Coronavirus Pandemic and It’s Impact on Manufacturing

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Since the start of the COVID-19 outbreaks in early 2020, there have been many different levels of impact on various industries. Some of these impacts were predicted, while others were wholly unexpected. Many of the long-term effects were significantly underestimated as we still see substantial challenges to supply chains and distribution. However, even in the face of a global pandemic, manufacturers and engineers still continue the development of new technology, smarter designs, and more sustainable systems. Throughout 2020, 2021, and now, as we continue through 2022, the stud welding industry faces changes brought on by the pandemic. Despite the difficulties, many still foresee similar market growth to that first predicted in early 2020. For anyone working with stud welding operations on a large or small scale, Northland Fastening Systems has the supplies and tools needed to get the job done. We provide a wide selection of stud welding products, including tools for rent or purchase, welding studs, accessories, and the support of our own technicians.

Predicted Market Growth

The predicted market growth for stud welding products and the welding industry in general was marred by a sharp decrease of about 3.5% of the global GDP in 2020. That decline, though significant, was not the 5.2% shrinkage predicted by the World Bank Group, and currently, the World Bank predicts a global economic expansion of about 4% in 2022.

Coronavirus

After the initial impacts of the coronavirus pandemic on the global economy, we seem to be entering the recovery period. By 2028, the market size will likely be far greater than its pre-pandemic equivalent.

Greatest Damage to Manufacturing

The greatest damage the pandemic did to the manufacturing world was the unanticipated severing of thousands of supply chains for multiple types of raw materials, parts, and other products. Illness among workers led to limited production time, forced plant delays, and decreased expertise, while government-mandated shutdowns over long periods of time severely lowered manufacturing, inventory, and distribution capabilities.

Government Loans

At the same time that government loans supported many companies, that assistance was not enough for some. Throughout 2020, mass layoffs and company closures led to almost 50 million people being unable to work. In 2021, that number dropped to around 8 million. As of now, the number of unemployed people in the U.S. is about 3.6%, which is the lowest since February of 2020.

Stud Welding Products

For the stud welding industry in particular, the most severe impacts of the pandemic are the supply chain shortages and delays we are still experiencing to some degree. At NFS, we’ve worked hard to continue to be a reliable resource for all our customers. We’re happy to say we’ve been able to keep supporting clients in the construction and industrial markets throughout the pandemic, and we plan to continue maintaining a comprehensive supply of stud welding products.

To learn more about our supplies and services, contact Northland Fastening Systems at (651) 730-7770. Request a quote online to get started with us today.

Automated Fastening Systems Entering the Fourth Industrial Revolution

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Industries are always changing as new technology develops and becomes commonplace. As new equipment and practices come into any industry, regulations and standards come with them, and manufacturers adapt to meet these requirements. In the stud welding industry, we use very different models and systems today than the formats that were used in the early 1900s for shipbuilding. The first stud welding operations were essentially manual stick welding or resistance welding, used for composite construction on navy vessels and other large ships. Today, stud welders have several operations at their disposal, including drawn arc, capacitor discharge (CD), and short cycle fastening systems. No matter what kind of modern stud welding you use, you can find the supplies, repairs, and advice you need at Northland Fastening Systems. NFS provides a complete range of supplies, from tools to accessories and everything in between.

Global Industrial World

The global industrial world has gone through several significant changes in the form of three major eras. The most significant early changes began with the First Industrial Revolution, from the late 1700s to the mid-1800s. This marked the change from handmade products to fabrication with steam and water-powered machines.

Second Industrial Revolution

The Second Industrial Revolution spanned the turn of the century, from around 1870 to 1915. This marked a time of economic growth, the development of larger railroad systems, and the modern production line.

Third Industrial Revolution

The Third Industrial Revolution began towards the end of the 1900s as digital technology, computers, and the internet changed the manufacturing landscape. This revolution led to today’s current status as the time of the Fourth Industrial Revolution, or Industry 4.0.

What is Industry 4.0?

The foundation of Industry 4.0 is the increased use of artificial intelligence, smart automation, data sharing, and interconnectivity. The internet and cloud systems allow for direct, in-depth data sharing between every production stage, engineers, customers, and third parties. This creates an immersive manufacturing environment that borders on augmented reality, guided through extensive technical assistance. Industry 4.0 gives all levels of manufacturing greater intelligence, the ability to make decentralized decisions, and data transparency.

What does automated stud welding mean for the industry?

Although Industry 4.0 has been slower to affect the stud welding industry and fastening systems in general, there are still new technologies, operations, and capabilities entering the field. Automation has been growing rapidly, material sourcing is improving constantly, and production speeds are at an all-time high. Innovative applications of stud welding are also growing, especially in the fields of design and infrastructure. Most importantly, safety standards, sustainable policies, and economic responsibility have shifted the paradigm of the industrial world, including for stud welding. Industry 4.0 is moving stud welding towards better data, less waste, and smarter tools.

To learn more about the high-quality fastening systems supplies we provide, contact Northland Fastening Systems at (651) 730-7770 or request a quote online today.