Category: Stud Welding

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

Welding Studs

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

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

Welding Studs with AHSS Materials

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

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

Summary

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

 

 

 

 

 

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

Steel Weld Studs

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

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

 More Uses

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

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

 

 

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

Stud Welding Supplies

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

Stud Welding Process

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

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

More Industries

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

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

 

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

Construction Welding

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

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

80% Industrial

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

20% Construction

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

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

Since its invention in the early 1900s, stud welding has proven to be an exceptionally useful tool for a wide range of industries. From construction to electronics, stud welding offers a fastening system that connects metals with strong, rapid, and clean operations. When applied correctly, stud welded connections are stronger than the stud and base material put together. In fact, one of the quickest ways to test the accuracy of a weld is by seeing if the stud will fail in a bend test before the connection point fails. If you are working with stud welding, you know the benefits it provides to many manufacturing processes. Stud welding is quick, cost-effective, and powerful. At Northland Fastening Systems (NFS), we provide a complete range of supplies for the drawn arc, capacitor discharge (CD), and short cycle stud welding process. This includes studs for each type of welding, tools for rent and purchase, welding accessories, and even repairs for most welding equipment.

Stud Welding Process

One of the reasons why the stud welding process is advantageous for so many industries is because of the strength a full fusion weld point provides. Stud welding operations completely fuse stud materials to surface materials. This fusion can be done with a variety of metals, including steel, aluminum, and even copper.

What Is Complete Fusion?

Complete fusion requires both metals to reach melting temperatures. Molten metals will fuse together at the weld point and create a complete connection between parts. All layers of stud and surface material should be molten in order to create complete fusion. Because of this requirement for deep penetration, stud lengths will shorten a specified amount when installed, depending on material and weld types.

A homogenous weld point that is completely fused will be clean with no spatter or puddles. Complete fusion eliminates the risk of a cold or porous weld that will likely fail. Any incorrect applications that have incomplete fusion can be revealed with testing. Incomplete fusion issues can be prevented by accurately calibrating welding equipment, using the right power, and performing a weld in the correct duration and positioning. With drawn arc welding, ceramic ferrules and shielding gas also help technicians achieve complete fusion in the welds.

Summary

For complete fusion through paint, annealing, and other surface treatments, technicians should adjust accordingly and use grounding clamps on the job site. In facilities where automated stud welding systems are integrated into a production line, complete fusion results are often built into the equipment. Automation parameters for complete fusion can be adjusted when stud dimensions, materials, and other specifications are changed.

If you are working with any kind of stud welding process in any industry, and are looking for supplies, equipment, and more, we can help. Contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.

Welding with an electrically generated arcing current was first developed in the late 1800s by several British, Russian, and American inventors. In 1887, Russian inventor Nikolay Benardos presented the first arc welding system with a carbon electrode. The same year, another inventor, French Auguste de Méritens, also developed a carbon arc welder. Over the next 130 years, new technologies for welding would be invented and developed to the advanced state-of-the-art systems they are today. Modern metal welding hosts an umbrella of operations from gas metal arc welding (GMAW) to electron beam welding (EBW). Stud welding is also a commonplace welding operation that is used across industries. If you are working with a drawn arc, capacitor discharge (CD), or short cycle stud welding process, you can find all the supplies you need at Northland Fastening Systems (NFS). NFS provides a complete selection of welding equipment, including tools for rent or purchase, welding studs, accessories, and even repairs for most models.

Stud Welding Process

Stud welding machines can utilize either AC or DC power supplies depending on the welding application and the facilities. The power source for any stud welding process can be one of three general designs: transformers, generators, or inverters.

Transformers:

Using electricity from main utilities, transformers convert moderate electrical currents and voltage into high current and low voltage. Generally that conversion takes 110–240 V supplies to around 17-45 V with anywhere between 55 and 590 amp. Transformers are less costly than other power supplies, but they can only be used within a facility because of their large size.

Generators:

For job-site welding with portable welders, a generator is often the best choice for power conversion. These designs convert mechanical energy into electrical energy with an electric or internal combustion motor. Generators are also called alternators because they convert that energy from mechanical to electrical to reach the same voltage step-down that transformers provide.

Inverters In the Stud Welding Process

Inverters are a newer power source for welding units because they use high-power semiconductors that have only recently been adapted into wider technologies. These systems take main utility AC and change it to DC, then they invert that DC power to step-down the voltage and change the current to the calibrated weld requirements. The most significant feature of inverters is that they can be adjusted with software systems thanks to their use of semiconductor chips.

Within these categories of transformers, generators, and inverters, there are many variations that can be used as power supplies for stud welding. Each type of stud welding and welding overall will require different calibrations of voltage and current that can be achieved with these power supply designs.

If you are in need of any supplies for your stud welding process, contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.

Since the first usage of stud welding in the early 1900s for the shipbuilding of freight, naval, and other large vessels, stud welding operations have become a mainstay for the maritime industry. Over the next 120 years, stud welding grew to be used in a broad range of industries in addition to shipbuilding, including the construction, electrical, and food equipment industries. While stud welding is widespread across the industrial world today, it continues to be a key operation for the maritime and, by extension, freight shipping industries. Because it is such a heavily used manufacturing operation for freighters, stud welding and steel weld studs in particular make container shipping possible and allow a trading economic system to exist on a global level. For any stud welding projects, Northland Fastening Systems supplies welding units for rent or purchase, CD and drawn arc studs, welding accessories, and more.

The Impact of Steel Weld Studs on the Shipping Industry

As we’ve said, freighters and other shipping vessels could not be made as efficiently and safely without the use of stud welding. The steel weld studs used to construct these vessels are what make container shipping a significant part of the global economy.

Container Shipping

Let’s look at some basic statistics from the container shipping industry made possible with stud welding (published as of 2022):

• 80% of all products traded worldwide are shipped by sea.
• In 2020, around 1.85 billion metric tons of goods were shipped around the world by freight.
• In the past 40 years, cargo ship tonnages have increased in capacity from about 11 million metric tons to around 275 million metric tons.
• Around 54,700 merchant ships operate globally.
• Some of those types of merchant vessels include general cargo, crude oil tankers, chemical tankers, container ships, and passenger ships.
• Shanghai handled 47 million tons of cargo in 2020, making it the leading global port for container shipping.
• New general cargo ship designs may produce 40% less CO2 emissions by 2040.
• The first standardized intermodal freight containers were developed in the 1950s.
• The first refrigerated freighters were introduced in the 1970s.
• The world’s largest cargo ship, the Ever Ace, measures 1,300 feet and has a holding capacity of 23,992 standard freight containers.

Steel Weld Studs to Meet the Needs of Today and Tomorrow

Modern freight shipping has reached massive proportions to meet the demands of a growing population and an increasingly capitalistic economy. Despite the futuristic systems and designs of today’s freighters, they still all rely on the use of stud welding and steel weld studs for construction.

Summary

To learn more about the abilities and uses of stud welding, contact Northland Fastening Systems at (651) 730-7770. Request a quote online to get started with our team today.

 

Because stud welding is used so prevalently throughout different industries, it shows its versatility in terms of applications and materials. Stud welding operations also have great flexibility when it comes to sizing, such as stud diameters and lengths. With stud welding, you can perform food-grade fastening systems, composite construction, large-scale thru-decking, and much more. If you are taking advantage of the wide range of the stud welding process for any project, big or small, you can find all the supplies you need with Northland Fastening Systems (NFS). We provide a complete supply of welding tools for rent or purchase, drawn arc, capacitor discharge (CD), and short cycle welding studs, welding accessories, and repair services for most models. Our own welding technicians are also available to provide support and advice from their own expertise and knowledge.

Stud Welding

For the majority of stud welding, steel is a mainstay material for drawn arc and CD operations, but there are many other materials that are critical parts of the stud welding process as well as materials that can improve and alter the properties of a weld.

Stud Welding Process

Let’s look at the material specifications for different components of the many steps that may be included in a full welding operation:

Studs and surfaces:

As mentioned, steel is a primary material for most stud welding scenarios. Low carbon steel and 302/304/305 stainless steel grades are common for drawn arc welding. However, for drawn arc operations, aluminum, other stainless steel grades, monel, and inconel can also be used for studs and surfaces. CD stud welding uses similar materials, including low carbon and stainless steel, but 1100, 6061, and 5000 aluminum alloys, brass, and other steels can also be used.

Plating:

For drawn arc welding, cadmium and zinc alloys can be used as plating. CD welding can use copper, cadmium, nickel, zinc, and many other plating metals. If nonweldable plating is already on a surface, that should be removed to prevent weld contamination.

Annealing:

Generally speaking, all low carbon and stainless steels can be annealed for both the stud and surface. Annealing can be done to a maximum of 75 Rockwell B for low carbon steel and 90 Rockwell B for stainless steel.

Ferrules:

An important nonmetal material used in stud welding comes in the form of a ceramic ferrule. Ceramic ferrules are a part of the drawn arc process. Ferrules are installed at the point of the weld around the stud tip to contain and control molten metal while the weld is performed. They can then be chipped off when the weld is cooled.

Summary

If you are looking for materials used in any part of the stud welding process, contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.

Welding has been a part of many metalworking industries for centuries, with the earliest forge welding dating back to the Bronze Age (3300-1200 BCE). Stud welding as one of many newer kinds of welding was developed in the early 20th century in the shipbuilding industry. Since its first advancements, stud welding has grown to be a part of almost every metal manufacturing industry from construction to food service. If you are working with stud welding operations, you can find all the supplies you need at Northland Fastening Systems (NFS). NFS is a comprehensive supplier of all stud welding equipment, tools, studs, and other accessories. We also provide repairs for tools and the advice of our own expert technicians. One application of stud welding that is sometimes overlooked is its use in food grade welding for restaurant, catering, and other commercial food service industries. Stud welding is a quick, clean operation that can create strong connections between stainless steel studs and other equipment components. Not only is stud welding effective for well-made equipment, it’s also sanitary. Equipment made with stud welding operations meets strict standards for food safety and hygiene.

Food Grade Welding

From commercial kitchens to residential appliances, food grade welding is a heavily relied-on operation that allows manufacturers to quickly build components and full assemblies that won’t have potential issues with hygiene. Food grade stud welding prevents harborage, creates strong connections, and uses stainless steel that won’t corrode or allow spaces for bacteria and other pathogens to grow.

A large part of the food service industry that utilizes equipment manufactured with stud welding is catering. Many kinds of equipment used in the catering industry are fabricated with CD stud welding, thanks to the strong, clean connections points it offers.

Catering Chronology

Catering in the world dates back to 4000 BCE in China, but catering in the United States has a much shorter history. Let’s look at a brief timeline based on an article on Medium.com website, “A Brief History of Catering.”

• 1778: One of the first large catered events was held in Philadelphia at a ball. The event was catered by Caesar Cranshell.
• 1820: By this time, catering was a respectable business that was largely operated by African Americans in the free northern United States.
• 1840: Robert Bogle, the “Originator of Catering,” expanded and diversified the catering industry.
• 1930-1960: The catering industry survived through World War I and World War II rationing by simplifying menus and partnering with restaurants.
• 1970-2000: During this time, as more and more women started working in the food service industry, new styles of cooking passed down in different communities became a part of catering menus.
• 2000-present: Catering is a dedicated department for many restaurants today. Catering has also changed to adapt to new concerns and rules after the COVID-19 pandemic. Current restrictions for sanitation and preventing pathogen transmission make it more important than ever for catering equipment to be hygienic.

To learn more about how catering equipment is made today with CD food grade welding and our supplies, contact NFS at (651) 730-7770 or request a quote online.

Thru-deck stud welding is an important operation for the construction industry and is utilized in a wide range of composite building processes, including attaching metal deck sheeting to steel beams. Decking and steel beams have widespread use in the construction of many kinds of buildings, infrastructure, and other large structures. Because thru-deck welding is such a critical part of many fabrication projects, it’s important for welds to be performed correctly, and for testing and inspections to follow international standards for quality. If you’re working with thru-deck welding processes, we can help. Northland Fastening Systems (NFS) supplies a comprehensive range of tools for rent or purchase, studs, accessories, repairs for most welding models, and the guidance and knowledge of our own skilled technicians.

Thru-Deck Welding

With thru-deck welding, you’re likely operating on an active job site, which means safety is key. Check your cables, equipment, and power source for safety and to ensure you’re receiving enough power through extended cords; make sure your welding surfaces are grounded to a clean spot on a beam; and check your welding surface for dirt, water, and other contaminants.

Once you’ve made sure your conditions are appropriate for thru-deck weld fastening systems and you’ve performed your weld, you should also test and inspect the weld results before continuing on to complete a series of welds.

Testing

Ideally, you will perform tests on pre-production and production weld results. All testing should follow the American Welding Society Structural Welding Code D1.1. This means accounting for the material and design, fabrication, qualification, and inspection. Many details need to be taken into account with your testing, including not performing a test in cold weather unless the stud has cooled to be warm to the touch. If a stud is hot or cooled completely in temperatures below freezing, it will compromise the results. Learn more about AWS testing standards and more about basic testing of stud welds.

Visual Inspections

Visual inspections are just as important as following the AWS code for thru-deck welding specifications. In your visual inspection, you should be able to see the weld point completely around the stud. Any undercuts, spattering, or other abnormalities at the weld point is a sign of a poor weld. If you can’t see 360 degrees around the weld, you may need to use destructive testing methods. This can be done with a hammer hit or by bending the stud to a 15-degree angle. In most cases, bending will be a more effective test. If the weld fails with either test, you need to recalibrate your conditions and test and inspect a new result.

Thru-deck welding is one of many useful stud weld fastening systems for the construction industry. For more information about our supplies for thru-deck and other welding operations, contact NFS at (651) 730-7770 or request a quote online