Accessories for the Stud Welding Process

Stud welding is a complex process in many ways, but simple in others. The operation of a stud weld itself is a strong but straightforward connection point that fuses the metal of the stud into the metal of the base material. However, the actual process takes a deep understanding of arc generation, materials, dimensions, and the tools involved. In order to perform an accurate weld, you need the background knowledge and the right tools for the job. At Northland Fastening Systems, we provide the tools, studs, and accessories necessary for drawn arc, capacitor discharge (CD), and short cycle processes. When it comes to the accessories important to any stud welding process, our team of expert technicians can help you find exactly what you need.

Since 1987, we’ve supported and worked to continually improve the stud welding industry. One aspect of stud welding that is often overlooked is the use of accessories in the CD and drawn arc process. These accessories are completely necessary for an effective end result, but they can be taken for granted sometimes.

For the drawn arc and CD stud welding process, NFS accessories include the following.

Drawn Arc Accessories:

CD Accessories:

NFS supplies a broad range of stud accessories that pair perfectly with industry-standard studs and welding tools. To learn more about the supplies that we provide for the drawn arc, CD, and short cycle stud welding process, contact Northland Fastening Systems today at (651) 730-7770 or request a quote online.

What to Consider before Buying Stud-Welding Equipment

With any kind of manufacturing tools, you need to do your research to determine what specifications, sizing, materials, and other details you’ll need depending on the job. Even with a simple tool type like a screwdriver, there is a large range of variations. When it comes to more complex manufacturing tools or whole systems like with stud-welding equipment, there are even more technical aspects to consider before purchasing even the studs you will use. Northland Fastening Systems (NFS) provides a complete range of stud-welding supplies from tools for rent or purchase to studs of any dimension, including customs options. In addition to a comprehensive supply of stud-welding equipment, our staff of knowledgeable technicians will guide you in selecting exactly the right tools, studs, and accessories you need.

While we at NFS make all our welding supplies as affordable as possible, we don’t want you to waste your time and/or money purchasing a tool or stud that won’t work for your job. To save yourself the headache of returns or wasted money, consider the following issues before buying stud-welding equipment:

Materials: Different stud-welding processes work best with different materials. If you’re working with thin stud-welding pins for stainless steel, food-grade welding, the best tools to choose will be for CD stud-welding operations. On the other hand, composite construction with bar anchors requires more heavy-duty tools for drawn arc welding. The surface material and the stud materials are both significant factors that will guide your stud-welding equipment choices.

Dimensions: Like the materials, the dimensions of the studs you’ll be working with will guide your selection of all stud-welding equipment.  CD stud-welding operations are suited to smaller studs like pins, insulator fasteners, and sheet metal connectors. Additionally, CD studs are best for thin surface materials because they don’t leave through-marking discoloration or warping. Drawn arc stud welding tools can handle larger stud dimensions and thicker base materials. Because they can handle much heavier duty dimensions, drawn arc welding studs are also used in building construction, structural steel applications, and composite construction for large-scale structures like bridges.

Automation: Another important aspect to consider before purchasing stud-welding equipment is whether you need options for automation or you’ll only be performing welds with hand tools. Automated tools can require different power calibrations, facility setups, and maintenance treatment. While handheld tools still perform rapid welds and are often useful as portable tools in the field, fully automated systems are key for many large-scale production operations. Determining whether you need automated tools for faster production will be a large factor in choosing the right stud-welding equipment.

To learn more about what you should consider before purchasing stud-welding equipment or to get started with us today, contact NFS at (651) 730-7770 or request a quote online.

 

 

 

Local Contaminants to be Aware of When Using Stud Welding Fastening Systems

Northland Fastening Systems provides supplies for operators using stud welding worldwide. From small shops to manufacturing plants and large construction sites, we supply tools for rent or purchase, studs in a complete range of dimensions, custom stud options, welding accessories, and the expertise of our welding technician staff. For drawn arc, capacitor discharge, and short cycle stud welding processes, NFS can provide everything you need to get the job done. If you’re working with stud welding fastening systems, it’s important to be aware of the potential problems that can be caused by a weld site’s exposure to local contaminants.

The most common issues welders face with local contaminants includes the following:

  • External gases: In many welding applications, shielding gas is a critical component of the process to protect the connection point from external gases that exist naturally around us. Exposure to prevalent gases like oxygen, nitrogen, and carbon dioxide around a welding site can cause porous, brittle connections. The use of shielding gases like argon or helium will create a protective bubble around the weld point, lending to stronger fastening systems.
  • Cold: While it’s not typically an issue, extreme temperatures can cause problems with stud welding fastening systems. Because welds will cool much quicker in cold weather than other more temperate conditions, cracking can occur with the shock of that temperature drop. Also, because the rest of a metal welding surface is typically much colder than the weld point, warping is also a potential issue. The easiest way to prevent these problems when welding in cold weather is to preheat a large area on your welding surface.
  • Particulates: Dust and other surface contaminants are one of the most significant concerns for welders using stud fastening systems. Particulates blown into a weld point can create a poor connection that is brittle or porous. Creating barriers outside and keeping your indoor welding spaces clean can solve many issues that dust causes.
  • Moisture: Humidity or other sources of moisture can cause issues for welders like corrosion on machines or damages to electrical systems. In severe cases, moisture can short circuit welding units and pose significant danger to operators and other workers. Keeping tools stored in dry, covered areas and maintaining a dry workspace solves many moisture issues.

There are other issues to be aware of such as tool maintenance, welding calibrations, material compatibility, and many additional aspects of the welding process, but these are the most common problems that operators face from contamination of a weld. NFS technicians can provide advice and guidance for working through any issues and equipment specifications you may need.

To learn more about stud weld fastening systems and our supplies and services, contact Northland Fastening Systems at (651) 730-7770 today or request a quote online.

 

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.