Category: Arc Welding

Drawn arc stud welding is one of the most important manufacturing operations in large-scale steel and composite construction. From its first key uses in shipbuilding to its common uses today in bridge construction, roadwork, automotive fabrication, and more, drawn arc stud welding has a large role to play in manufacturing industries. Because it is so important to a range of industries, stud welding technicians need to have a deep understanding of what makes a strong weld and why. If you are working with stud welding for any project, Northland Fastening Systems (NFS) has stud welding tools for rent or purchase, studs in a comprehensive range of dimensions, stud welding accessories, and the expertise of its own stud welding technicians—all to help you get the job done correctly and efficiently.

 

Drawn arc stud welding has a large range of specifications, calibrations, and additional factors to take into account. Without delving into the numbers and precision often needed to provide a strong weld connection, every technician should know the four basic properties involved:

 

• Surface Preparation: Drawn arc stud welding can vaporize thin layers of contaminants like paint, rust, or oils, but before welding, surfaces should still be prepared correctly to ensure a strong connection. Any thick coatings must be removed as metal-to-metal contact during the weld is critical to generate an arc. If thicker coats cannot be removed, you’ll need a mechanical punch to create a metal-to-metal connection.
• Ferrules: Drawn arc stud welding uses ceramic ferrules around the weld point. These ferrules contain molten metal during the weld to prevent splatter and shield the arc as it is generated. These ferrules also prevent air flow into the weld to control oxidation, and they protect nonmetal materials around the weld point from charring. Ferrules are chipped away from the weld point when the stud and surface material cools.
• Shielding Gases: Inert or semi-inert shielding gases are typically made up of 100% argon or a mixture of argon and helium. These gases protect a drawn arc stud weld point from oxygen and water vapor during the weld. Shielding gases can also be generated with a flux that outputs a semi-inert gas like carbon dioxide when heated in the weld.
• Flash: Every stud weld creates a flashing of molten metal around the connection point. This flashing can be a sign of a good or bad weld depending on its condition. In a drawn arc stud weld, flashing should be within the ferrule containment and show complete fusion around the entire stud. If you were to take a cross section of the weld, that fusion would be around the base of the stud beneath the surface as well.

 

Drawn arc stud welding is a complicated process that is used in a broad range of applications. To learn more about drawn arc stud welding, contact Northland Fastening Systems (NFS) at (651) 730-7770 or request a quote online.

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

 

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

 

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

 

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

 

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

 

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

 

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

Many forms of welding have been used for centuries to build strong, long-lasting parts and countless buildings and other structures. Included in these forms of welding are the various types of stud welding, all of which provide one of the strongest connection points of any weld type. In fact, both capacitor discharge (CD) and drawn arc stud welding form a bond that is stronger than either the weld stud or the base material.

 

Because of the strength of these connections, stud welding is an operation that is key to many manufacturing industries. No matter what industry you work in, Northland Fastening Systems has the tools, supplies, and services you need for both drawn arc stud welding and CD stud welding.

 

We are committed to providing a comprehensive range of welding studs in multiple standard dimensions as well as custom made-to-order studs. In addition, we offer welding tools for rent and purchase and our own expert services.

 

When it comes to drawn arc stud welding in particular, determining the required stud specifications is critical for a strong, lasting weld that can hold the weight or other stresses it will bear. Typically, drawn arc stud weld points are used in heavier construction projects and require precise performance in the field. This performance depends on the strength of the weld point, which in turn depends on weld fusion and weld penetration.

 

Weld Fusion

Simply put, weld fusion is the point where the metal of the stud connects to the metal of the surface. This fusion is a chemical connection generated by the heat of the welding arc rendering both stud and surface metal and joining those points with an atomic bonding process. In order to have a strong, reliable weld point, the spread of the fusion must be as far up the stud, as deep into the surface, and wide enough in diameter to create the necessary connection.

 

Generating the correct level of fusion without using unneeded energy or compromising the stud requires a highly specific combination of time, power, and force. For the majority of drawn arc stud welding operations, these combinations are predetermined by industry engineers specializing in stud welding physics. These specifications can be applied to different welding projects within a varying range that gives the welder the information needed to apply the correct level of weld fusion and create a strong weld connection.

 

NFS welding technicians can help you determine the specifications you need to apply precise, high-quality drawn arc stud welding operations to your project. To learn more about weld connection points, our stud welding services, and the welding studs we provide, contact Northland Fastening Systems at (651) 730-7770 today or request a quote online. Learn more about welding fusion here.

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.

 

Over the last 200 years, humanity has discovered hundreds of ways to utilize a steady flow of electrical energy. Today, these applications make up an enormous range of hardware, software, and other tools for extensive varieties of circumstances. To successfully use electricity, the development of other highly specific tools was necessary. One example of a common tool used to accommodate the needs of many electronic systems is an electrical enclosure. These enclosures are suited for countless applications of electrical energy, and they can be built in many different ways. At Northland Fastening Systems, we’ve found the most efficient, reliable, and highest quality ways to build electrical enclosures is with arc stud welding.

 

NFS offers stud welding services, stud welder rentals, and stud welding accessories suited for a comprehensive range of stud welding operations. Since 1987, we’ve provided stud welding services for several industries, including building electrical enclosures. Using drawn arc stud welding, you can quickly build a reliable electrical cabinet with a pristine exterior and solid structural integrity.

 

Electrical enclosures serve as a housing system for circuit boards, electrical equipment, switches, screens and other displays, gauges, dials, and many other features necessary for an electronic system to function. In addition to housing and supporting these components, electrical enclosures also protect a system from surges, corrosion, and exposure to other elements.

 

With NFS high-quality drawn arc stud welding supplies, you’re able to build electrical enclosures meeting a wide range of the National Electrical Manufacturers Association (NEMA) standards. NEMA enclosure standards outline requirements for more than twenty enclosure types. Some of the most common enclosures include:

 

• Type 1: General purpose enclosures protect against dust, light and UV radiation, and some splashing. These cabinets are suited for indoor use for a wide range of common electrical systems.
• Type 2: These electrical enclosures are similar to Type 1 cabinets but are suited for additional protection against dripping and heavier humidity.
• Type 3: Designed for weather resistance in average conditions, these enclosures protect against rain, wind-blown debris, sleet, snow, falling dirt, and even ice.
• Type 4: Electrical enclosures falling into this category are watertight and resistant to corrosion. They are often used outdoors, offshore, and in other locations that are frequently exposed to moisture.
• Type 5: These cabinets are designed to prevent dust from permeating the exterior. They are critical for components used in mills and factories.
• Type 6: While Type 4 electrical enclosures are watertight, they can’t match the water resistance of a Type 6 submersible cabinet. Submersion in water or oil for extended periods of time without damage is possible with a Type 6 enclosure.

 

Meeting NEMA standards for all electrical enclosures is possible when using the manufacturing capabilities offered with drawn arc stud welding. For a clean, quickly, and reliably made electrical enclosure, NFS is your one-stop-shop for tool rentals, welding services, and stud accessories. Contact us at (651) 730-7770 or request a quote for more information.

 

Arc welding is a type of stud welding technique with specific applications we’ll cover in this article.

In today’s post, we’ll show you why arc welding is so effective, which materials it works best for, and provide recommendations for using arc welding based on the job, industry, and more.

Before we dive into the topic of arc welding itself, let’s talk about the benefits of stud welding for metal workers.

The Stud Welding Difference

You’ve heard the concept of welding before.

It’s simple – welding is the process of connecting one metal to another. You can use a variety of techniques like x, y, and z.

Stud welding saves time, money, and materials by creating a more efficient way to connect these metals. With arc welding, the stud joins the piece of metal instantly because it heats the stud and metal at the same time.

You may be wondering why this is important.

Joining the stud and the metal at once creates a tightly knit and more durable bond. This means the structure you build with arc welding will maintain its strength longer.

There’s also less room for error and the need for rework. When you don’t use stud welding, you need more effort and put yourself at risk of having to reweld that part if the bolts don’t connect properly. Also, the “clinching process” of welding isn’t as strong or long-lasting as stud welding because the bond isn’t as strong as heating multiple parts at once.

You can see how this would lead to cost savings, too. It’s a simple equation — less labor time, less need for re-work, and fewer materials needed equals lower cost.

At Northland Fastening systems, we promote stud welding not only because we sell stud welding products, but because the process is simply better and easier. 

Let’s dive into the need to know details of arc welding and how it can apply to your needs.

Arc Welding Explained

In the arc welding process, the electric arc fuses metal together with heat generated by the electricity. This method differs from using gas, which is less efficient.

Arc welding can use both DC and AC electrical currents. This is important because not all welding units accept both currents. Arc welding fuses the stud using an electrode. This electrode conducts the electricity needed to generate the heat.

When arc welding, you can feed the electrode automatically over and over again. Why is this important?

There are certain processes that benefit from this automated technique:

• Flux Cored Arc Welding (FCAW)
• Gas Metal Arc Welding (GMAW)
• Submerged Arc Welding (SAW)

If your machine shop or manufacturer uses these processes, arc welding helps complete them in the most efficient way.

The process also saves time in the following ways:

• No need to switch parts like filler rods
• Less chance for heat distortion – in other welding processes, spreading out the heat too much can distort the parts being fused together.
• Decreases deposition rate – meaning you won’t use as much metal
• Switching from manual to automatic processes (when this applies)

If you’re a machine shop owner or operator, the technical benefits are clear.

For purchasers working for companies with manufacturing needs, you can talk to your company about switching to this often easier and more efficient process. In many cases arc welding can be a more affordable solution because the process requires less equipment.

Applications

It’s important to know how this process works for different needs and industries.

It’s a process that works well for many applications, but here are some core industries where it works best.

Sheet Metal Fabrication

Sheet metal fabrication is often used for these industries:

• construction – commercial, residential, and industrial
• manufacturing equipment
• kitchen equipment
• elevators
• shipbuilding – specifically hydraulic presses

Here’s the main benefit of stud welding for sheet metal fabrication — appearance.

Stud welding fuses metals together without leaving many marks. Think about the benefits of this seamless process. Your equipment, parts, and structures will have the look and feel of a precision part formed from scratch, even though the parts are fused together. This gives an added professional look. Details matter in all structures and having that clean look and feel can make a better impression on people who see them.

Again, the process is also more efficient because of the speed and it creates more durability.

Agriculture Equipment

To explain the process simply, different types of agricultural equipment have many large pieces of metal that are fused together like the chassis, cab frame, fenders, and brackets

The farm industry requires durable and strong parts for its equipment. The stud welding process is used in some of the most important machinery in the world.

It’s best to use the stud welding process in an industry we all rely on so much.

Lawn and Garden Equipment

Similar to agriculture equipment, although not as large in scale, you want your lawn and garden equipment like lawn mowers to have tightly fused and strong frames.

Other outdoor equipment like barbecues benefit from the seamless look of having arc welded parts

Hospitals, Schools, and Other Facilities with Industrial Needs

We won’t dive into the details of the large number of different pieces of equipment needed to run these facilities.

The point here is to focus on the importance of having a quick and reliable solution in industries where efficiency has a big impact.

Anytime you are working on a large project, time and money are of the utmost importance. Loss of materials, time spent on rework, the need for more labor, and less efficient processes can have a huge impact on your bottom line.

If you are building a new facility or revamping your current one, consider a stud welding solution to meet your needs quickly and in a cost-effective way.

Your Next Step

If you need help with understanding our arc weld inventory, have questions about stud welding for your business, or you’re ready to make a decision, contact us now.

You can request a quote online, visit our contact us page and send a question, or call us directly at 651-730-770.

Let us help you with all your metal working needs.