Testing Stud Welding Results

Like in any manufacturing industry, diagnostics are critical for production utilizing stud welding in any capacity. Since its first use in the shipbuilding industry during the early 1900s, stud welding has expanded into many types of fabrication, from composite construction with shear connectors to thin insulation fasteners built into many structures. No matter what type of capacitor discharge (CD), drawn arc, or short cycle stud welding applications you work with, Northland Fastening Systems (NFS) has the supplies you need. Our selection of stud welding supplies includes tools for rent and purchase, studs in a comprehensive range of dimensions, custom stud options, welding accessories, and the expertise of our own staff technicians.

 

Stud welding operations can be complex, depending on the weld, stud, and material types. Because of this, results diagnostics are key to determine whether a weld process needs any adjustments. Even simple welds with pre-calibrated tools require basic testing to see if a connection point is strong.

 

Basic Testing

There are standard mechanical and visual diagnostics that can be done to check the first few welds after calibrating a tool for the dimensions, weld type, and surface material, including:

 

  1. Form two test welds to an approved base plate material sample.
  2. Inspect the weld to see if there are visible flaws such as spattering, burring, slag, and so on.
  3. Bend each test weld to a 30-degree angle from its vertical point. This bend can be done with a hammer, pipe, wrench, or other tool depending on the stud diameter.
  4. Inspect the weld connection to see if cracks or other flaws have appeared after the stud was bent.
  5. If no flaws appear and the test weld passes initial visual inspections, you can continue with that calibration for the rest of your job using those stud and base plate specifications.

 

Threaded Stud Testing

When using threaded studs, similar basic mechanical and visual tests can be done. Like the preceding weld tests, inspect two welds to an approved base material sample to see if visual flaws are apparent.

 

To perform a mechanical test for a threaded stud, set it in a secured steel sleeve. Then apply a tensile load by tightening a nut and washer down to the sleeve with a torque wrench.

 

Other Tests

 When testing studs that must be attached to non-approved base plate materials, apply visual, tensile, and bend tests to at least 10 weld samples. These tests should be done until a stud failure. An accurate weld will see failure in the stud from metal fatigue, caused by repeat bend tests, rather than at the connection point.

 

Low-temperature welds can also be tested with a slow bend to 30ºF using a pipe. Impact tests are not useful when welding in low temperatures (50ºF or below).

 

Accurate testing can protect your final results from potential failure in any stud when applied in an assembly. To learn more about stud welding and the supplies and expertise we provide, contact NFS by calling (651) 730-7770 or requesting a quote online.

Part One: Shielding Gas and Its Role in the Stud Welding Process

In many manufacturing industries, stud welding is often relied upon for its ability to create powerful fastening systems quickly and cleanly. The industries that the stud welding process is utilized in range from food grade manufacturing to composite large-scale construction.

 

As a type of arc welding, the stud welding process is capable of forming connection points that are stronger than the stud or base material. There are several types of stud welding processes, including drawn arc, capacitor discharge (CD), and short cycle welding.

 

At Northland Fastening Systems, we provide a comprehensive supply of tools, studs, and accessories for each stud welding process as well as the expert advice of our own technicians.

 

Compared to other types of arc welding, stud welding is a relatively straightforward process with few bells and whistles required to perform a strong weld. For example, technicians performing other welding processes require significant personal protective equipment and often shielding gas, slag, vapor, or other weld protective measures must be taken. The stud welding process is designed to be performed rapidly, easily portable in the field, and require only basic training for the welding technician.

 

CD and short cycle welding in particular are streamlined, fast operations compared to many other welding techniques. However, they are only suitable for a “lightweight” range of duties and are limited to smaller studs and overall moderate applications. Drawn arc welding, on the other hand, can be used in large-scale applications like composite construction for bridges and buildings. Because drawn arc welding utilizes additives like shielding gas and ceramic ferrules that other arc welding processes use for various operations, it’s capable of installing larger studs and heavy-duty manufacturing.

 

Typically, drawn arc welding uses a ceramic ferrule ring to contain the heat generated at the weld point and a flux tip to control the melt temperature. Using these additives in the stud welding process helps control the fusion and create a clean weld result. Welders can also use shielding gas in the place of a ferrule ring.

 

Shielding gases like argon, carbon dioxide, and helium are inert, and when applied during the welding process will protect the weld from air contaminants like water vapor and oxygen that would otherwise create a porous weld prone to cracking and corroding. When applied in a drawn arc stud welding process, shielding gas also helps control the arc, prevent splatter, vary penetration depth, and more.

Buyer’s Guide to Choosing the Right Welding Equipment

Whether you’re an experienced stud welder or just getting into the different types of stud welding that are each highly useful in its own way, selecting the right welding equipment can be difficult. Each welding unit and welding gun has its own set of exacting specifications, including power requirements, calibration ranges, material requirements, and much more. At Northland Fastening Systems (NFS), we offer a comprehensive range of stud welding equipment and other stud welding supplies, including tools for rent and purchase, studs in a broad range of dimensions, custom stud options available, and stud welding accessories. In addition to our extensive collection of stud welding supplies, our welding technicians offer their own expertise in the industry. Our team of knowledgeable stud welding technicians work with customers to help them select the right welding equipment so they can get the job done efficiently.

 

Choosing the right stud welding equipment can be difficult because there are many factors to take into account. The most important considerations before choosing a stud welding unit or gun include the following:

 

  1. Power source: Knowing your power source before selecting any welding equipment is key. Not only is it important to know whether your power source will be capable of providing enough welding power, some stud welding equipment requires a transformer or inverter, while others will need a capacitor discharge source.

 

  1. Arc generation: Drawn arc, capacitor discharge, and short cycle welding all use a different type of arc. Because of this, you need to understand how your welding arc will be generated and determine if your energy source will be capable of providing the necessary direct current.

 

  1. Weld time: For any production job, one goal is to limit downtime and work with the greatest efficiency possible. Many stud welders will use rapid welding operations to their advantage and build a schedule around how many welds per minute are possible. Not only do welds per minute vary between types of stud welding operations, they also vary between machines. Knowing the weld times you’ll need to meet production schedule requirements is a significant factor that will guide your selection.

 

  1. Weld abilities: Finally, one of the most important factors to consider when choosing welding equipment is what abilities that equipment has. Do you need a tool to perform CD welding or drawn arc welding? Are you working with steel or aluminum? What kind of surfaces are you welding on? What size studs will you be working with? All of these questions determine the capabilities of your welding equipment and should guide your decision when selecting which tool to work with.

 

To learn more about welding equipment specifications and which tool is right for you, contact Northland Fastening Systems at (651) 730-7770 or request a quote online today.

 

Stud Welding Market Growth

A recent comprehensive study done through ICRWord Research estimated a significant growth in the global stud welding market over the next five years. This forecast of trends and overall growth considered several aspects of the industry, including the major suppliers, geolocations, and specialized sections of each industry. Because we play a part in the global stud welding industry, we at Northland Fastening Systems (NFS) know how important it is to understand market trends. NFS supplies a complete range of stud welding supplies from stud guns for rent or purchase to a wide choice of stud dimensions.

 

There are many reasons why there is a forecasted growth in the global stud welding market even in the face of a global pandemic. While the market growth can be broken down into details as specific as #-thread count stud sales, generally speaking, there are some aspects in our changing world that have contributed to projected increases in the market. Some significant factors include the following:

 

Population and world growth: Because Earth’s population is continually increasing, it’s understandable that demand for products made with stud welding practices would also increase. In addition to an overall upturn in demand from population growth, there is also a rise in developing nations. Countries that in the past showed lower demand for new stud welded products are now generating their own increases in demand for common goods like automobiles, food industry equipment, electrical equipment, and more. This also includes increases in city planning, leading to the need for more stud welding construction projects like bridges and housing complexes.

 

Technology advancements: We live in a time of extreme technological growth. Smart technology is just the tip of the iceberg when it comes to the new designs and engineering involved in many tools used globally. From electrical enclosures to shipbuilding, stud welding is indispensable for a large number of advanced products in the manufacturing world today. Because stud welding is such an efficient and clean operation, manufacturers work it into a new design whenever possible.

 

Online distribution: Accommodating increased demand for stud welding products globally wouldn’t be possible today without the capabilities of online distribution. Digital distribution systems with the help of WiFi and online processing systems help suppliers get a wide range of stud welding products where they need to go quickly, accurately, and efficiently. Processing products with high-powered software systems and logging tracking data digitally is a key part of the industrial grade online distribution of stud welding supplies.

 

Increased demand from a growing population, newly developed countries, and more advanced technology set up the potential for serious market growth. That, paired with the extreme efficiency and capabilities of online distribution, are a large part of the market growth forecast for the next five years.

 

To learn more about the stud welding supplies we offer, contact Northland Fastening Systems at (651) 730-7770. You can also request a quote online to get started with us today.

Stud Welding Equipment Highlight: HBS Visar 650

At Northland Fastening Systems (NFS), we work with clients who are handling a broad range of jobs, from food grade stud welding to large-scale construction. To help our customers finish projects, we supply everything they need for stud welding operations, including welding studs in many dimensions, custom stud options, welding tools for rent and purchase, stud welding accessories, and the expertise of our own technicians. When it comes to the stud welding equipment we offer, customers can benefit from a broad range of stud welding tools that meet exacting specifications for electrical sources, weld calibrations, and other job requirements. One of the newer models we offer is the Visar 650, which meets some specific requirements that many other types of welding units don’t.

 

The Visar 650 is a drawn arc welding and short cycle welding unit that has maximum welding rates and efficiency as well as minimum weight and energy consumption compared to many other similar models. Thanks to HBS inverter-capacitor charging technology, the Visar 650 is able to offer a single phase 110v to 240v option. Because most similar stud welding units require a three-phase connection at 230v or 460v, they are much more restricted than the Visar 650. The option for single phase and 110v to 240v specifications means the Visar 650 can be used on a larger range of job sites and with more standard electrical outputs in residential or commercial settings.

 

The Visar 650 can weld studs between 12ga thru 3/8” (3-10mm) diameters.  We can accommodate any length greater than 5/8”.  The welding rates can be up to 40 studs per minute depending on the weld base diameter.  Both stainless steel and mild steel studs can be used with the Visar 650. The power range for the Visar 650 is 100v to 240v, with single phase electrical distribution.

 

Thanks to its power requirements and a 2-pin grounded safety plug, the Visar 650 is a versatile stud welding unit capable of being moved and installed in many different worksites. An F-type temperature-controlled fan prevents overheating, and a 15.91′ welding cable gives technicians a broad range of movement. As a smaller unit (approximately 18′ x 13′ x 14′) with a handle, the Visar 650 is easily ported from worksites. For any drawn arc welders working in setting with standard U.S. electrical specifications, the Visar 650 is the perfect stud welding equipment choice.

 

To learn more about the Visar 650 and our other drawn arc welding, short cycle welding, and CD welding units available for rent or purchase, contact Northland Fastening Systems at (651) 730-7770. You can request a quote online to get started with NFS as your supplier of stud welding equipment.

Working through the Numbers for Your Stud Welding Equipment

The widespread use of stud welding in the manufacturing world, attributed to the broad variety of stud welding applications, can sometimes be misleading. While a diverse range of welding operations, materials, equipment, and dimensions are standard in stud welding practices, the calibration, sizing, and material requirements for each combination of factors create very complicated differences between any given stud welding operation. Sometimes the differences in weld specifications are extreme, which means that welding technicians need an exact understanding of what is and isn’t possible with their stud welding equipment. No matter what types of stud welding equipment, materials, and dimensions you work with, Northland Fastening Systems (NFS) can provide the tools and studs you need to get the job done.

Breaking down the numbers specific to the stud welding equipment, processes, sizing, and materials you’re working with can be a difficult task. To work through these numbers, we’ve listed basic specifications into the following charts.

 

Stud Diameter Drawn Arc Stud Welding CD Stud Welding
1/16″ to 1/8″ Not effective Effective with standard procedure
1/8″ to 1/4″ Limited applications Effective with standard procedure
1/4″ to 1/2″ Effective with standard procedure Effective with specialty procedure
1/2″ to 1″ Effective with standard procedure Not effective
1″ to 1 1/4″ Limited applications Effective with standard procedure
Over 1 1/4″ Effective with standard procedure Not effective

 

Stud Material Drawn Arc Stud Welding CD Stud Welding
Carbon Steel Effective with standard procedure Effective with standard procedure
Alloy Steel Effective with specialty procedure Limited applications
Stainless Steel Effective with standard procedure Effective with standard procedure
Aluminum Effective with specialty procedure Effective with standard procedure

 

Base Material Drawn Arc Stud Welding CD Stud Welding
Carbon Steel Effective with standard procedure Effective with standard procedure
Alloy Steel Effective with specialty procedure Limited applications
Stainless Steel Effective with standard procedure Effective with standard procedure
Aluminum Effective with specialty procedure Effective with standard procedure

 

Base Metal Thickness Drawn Arc Stud Welding* CD Stud Welding**
Under 0.015″ Not effective Effective with specialty procedure
0.015″ to 0.062″ Not effective Effective with specialty procedure
0.062″ to 0.125″ Limited applications Effective with standard procedure
Over 0.125″ Effective with standard procedure Effective with standard procedure

*Base metal thickness should be at least a third of the weld diameter for best strength.

**Base metal thickness should be a minimum of 0.020″ to prevent weld melt-through.

 

No matter what type of stud welding specifications you are working with, NFS can supply a comprehensive range of tools, studs, accessories, and other stud welding equipment. To learn more about standard, specialty, and limited processes for drawn arc and CD stud welding, contact NFS at (651) 730-7770. Request a quote online to get started with us today.

 

 

 

 

 

 

 

Stud Welder Product Profile: HBS IT 3002

At Northland Fastening Systems (NFS), you can find everything you need to get the job done without running into inconvenient obstacles or compromising quality. We offer a diverse range of stud welding units for rent or purchase in addition to studs in comprehensive dimensions, accessories, and the expertise of our stud-welding technicians. Whether you need a portable handheld CD stud welder or a heavy duty automated drawn arc welder, you can count on NFS as your one-stop shop for stud welding projects. For short-term projects, we offer a broad stud welder selection for rent, and for dedicated welding technicians, we have a wide range of high-quality welding units for sale.

One of our favorite drawn arc welding units for heavy-duty stud welding in a large-scale construction setting is the HBS IT 3002. This welding unit is a dual gun drawn arc welder with a stepless current range between 300 and 2600 A.

The IT 3002 has welding capabilities for stainless steel, mild steel, and aluminum with stud ranges up to 1″ diameters. Welding times with the IT 3002 are 5 to 1,500 msec, depending on the stud dimensions and surface materials.

Application abilities: The IT 3002 is a construction-grade welding unit capable of through-deck welding and other industrial applications. Its best applications include thick sheet metal welding (2 mm or thicker) and composite construction such as concrete anchors, shear connectors, and deck welding.

Weld variations: Welding with the IT 3002 means working with a ceramic ferrule and drawn arc processes. It is also possible to calibrate the unit for short cycle drawn arc welding, and shielding gas is a built in option.

Unit dimensions: Because the IT 3002 is a unit for construction-grade welding, it is on the heavier and larger side. The full unit weight is 352.7 lbs (160 kg) with the dimensions of 25.6″ x 22″ x 50.8″. Though the full unit is a bulky tool, it is relatively easy to move from site to site with wheel and handle attachments.

Additional features: Thanks to features such as a precision-based microcontroller, continuous internal system function monitoring, lift test capabilities, and fine-tune adjustment ability with the library/specification function, the IT 3002 is a highly effective, reliable unit for even the most rigorous industrial applications.

Safety: In addition to excellent quality and precision control during the welding operation, the IT 3002 has several built-in safety measures. These includes a mains filter that protects against voltage peak, making it optimal for large mains voltages on construction sites. Additional features include lock-out triggers, thermal monitoring, and temperature regulations.

Overall, the IT 3002 is a compact construction-grade unit that is mobile and easy to operate. To learn more about this unit and other stud welder units we offer, contact Northland Fastening Systems at (651) 730-7770. You can also request a quote online to get started with us today.

The Three Best Questions to Ask Your Stud Welding Supplier

Northland Fastening Systems is dedicated to providing the best supply of stud welding equipment and services, from customized weld studs to tools for rent or purchase. We offer everything you need to get the job done, no matter how big or small, with drawn arc and CD stud welding supplies. We understand that our role as a stud welding supplier requires an understanding of the needs of our customers and support of quality production for our products and how they will be used. If you are searching for quality stud welding tools, weld studs, accessories, and excellent service, Northland Fastening Services (NFS) is your answer.

 

When looking for a quality stud weld product supplier, there are three questions to ask each potential company to ensure you’re getting the best of the best for stud welding tools and services.

 

What stud welding experience do you have?

 

NFS has over 30 years of experience in the industry. Since then, we have always been ahead of competitors in capabilities, supply of new devices, and available stud types. Not only do we have experience in some of the first digital stud welding programs and automated devices as well as today’s state-of-the-art technology, we are also well versed in portable, hand-held stud welding guns for a wide range of jobs. When it comes to quality service, NFS is unparalleled. We have technicians on hand for any support needed, and our customer service representatives value all of our customers.

 

Can you customize my options?

 

NFS offers comprehensive customizing services for our CD and drawn arc welding studs. Our readily available sizes cover a broad range of dimensions and thread count, but if special sizes are necessary for your project, we’re able to tailor your options to fit your needs. Our team of expert stud welding technicians is at hand to help you get what you need no matter what job you need to get done.

 

What technical support can you offer?

 

In addition to offering customized CD and drawn arc weld studs, NFS technicians provide complete technical support, from advice and guidance to full repairs and service. Our technicians can repair a broad range of stud welding models of equipment, including common brands like HBS, Tru-Weld, ProWeld, ERICO, AGM, MFI, NOVA, Cutlass, Nelson, and Tension Control Tools. While your equipment is being serviced, we also provide tool rentals so you can continue working even when your own equipment is down.

 

From technical support to custom studs and everything in between, NFS can give you everything you need to start and finish your stud welding project. Contact Northland Fastening Systems at (651) 730-7770 for all your stud welding needs. Request a quote online to get started with us today.

 

Different Applications of a Handheld or Automated Stud Welding Gun

Stud welding is a heavily used manufacturing application in the industrial world, and because of this, there’s a broad range of things that stud welding can do. From shipbuilding to food industry equipment, stud welding provides fastening systems for many types of components and full assemblies.

 

This diversity is also because there are, within stud welding itself, multiple methods of performing a weld. When it comes to different stud welding guns, the two primary tools are handheld guns or automated production gun systems.

 

At Northland Fastening Systems, no matter what type of stud welding gun you’re using, you can find studs, pins, bar anchors, stud welding accessories, automation devices, and everything else you need to get the job done. We also offer many types of welding units and tools for rent or purchase if you need to start from scratch.

 

The two main types of stud welding guns, handheld and automated, perform similar tasks, but do them in very different ways. The end result of a weld connection may be the shared feature of each type of stud welding gun, but the many differences between them each have their own benefits that might be more or less fitting depending on your production situation.

 

Handheld Gun

A handheld stud welding gun is a versatile option for welders on the go. They’re typically portable, small, and easy to set up in multiple locations. Handheld guns offer quick on and off-site welding options, providing flexibility and adaptability. Handheld guns can also be used on hard-to-reach surfaces or surfaces that can’t be passed through an automated system. Most handheld gun applications are for post-construction additions, maintenance, or complex building. Our handheld guns can create powerful connections and are easy to set up and use in almost any location.

 

Automated Gun

Automated stud welding guns are high-powered rapid welding systems. They’re typically used for production of components prior to any assembly. Sheets of material can pass through an automated system, welding hundreds of connections in a short period. If you’re manufacturing components that’ll be used in construction in your facility or shipped to a customer’s production floor, automated stud welding guns are highly beneficial. Automated systems can also be programmed and controlled through a software program. This can protect your welders from potential dangers of the welding process and improves precision from weld to weld.

 

Both handheld and automated stud welding guns are available in capacitor discharge (CD) or drawn arc welding formats. Which type of gun and welding format you choose will depend on your production location, the surface you will weld to, the stud dimension and material you use, and how fast you need a weld performed.

 

To learn more about the CD and drawn arc stud welding gun options we offer, contact Northland Fastening Systems today at (651) 730-7770, or request a quote online to get started with us.

Why International Certification Is Important for Stud-Welding Equipment

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

 

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

 

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

 

Other pluses include improvements to:

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

 

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