Selecting the Right Steel for the Insulation Fastener Stud Welding Process

Stud welding is used so prolifically across widely different industries that it often pops up in unexpected applications. Not only is stud welding used extensively in the automotive and construction industries, it’s also effective in building food-grade equipment, electrical enclosures, and even insulation and roofing. No matter how you are utilizing stud welding, you can find the supplies you need at Northland Fastening Systems (NFS). We provide a comprehensive range of welding studs for drawn arc, CD, and short cycle welding with additional options for custom dimensions. NFS also offers welding tools for rent or purchase and stud welding accessories. Our team of expert technicians has the training and skills to help you get whatever tools you need to complete your stud welding process.

 

Stud welding is a key operation for composite construction, including in building insulation and roofing. When it comes to welding insulation fasteners and roofing components, it’s important to select the right type of stainless steel for the stud welding process you’re working with.

 

All materials used in welding insulation fasteners must meet the standard guidelines of the American National Standards Institute (ANSI) and the American Welding Society (AWS). Within these standards, stainless steel grades typically approved are 300s in non-magnetic states with basic annealing. This includes 302, 304, 305, 309, 310, and 316. While 304 (also listed as 18/8) and 305 are the most commonly used in typical insulation fastening and roofing component welding, other stainless steel grades in the 300s are beneficial in their own way for certain applications.

 

Steels in the L series, like 316L, are often the most effective choices when resistance to corrosion is critical. In high heat applications, SS series like 320SS and 330SS are most effective, but for extreme temperatures and refractory applications, super alloys like Inconel 601 are more effective than stainless steels. Stainless steel temperature ranges for the insulation fastener stud welding process vary between 1,400ºF and 2,000ºF, while Inconel is used in applications around 2,200ºF. Steel grades 302, 304, and 305 are best at 1,400ºF applications, and 316 is best at 1,700ºF, 310 is best at 1,850ºF, and 330 is best at 2,000ºF.

 

No matter what insulation fastener and roof component stud welding process you’re utilizing, choosing the right stainless steel or other material is a requirement. Plan ahead your production schedule with attainability and lead time of acquiring different steels in mind. While many steel types are easy to source, some need to be special ordered with longer lead times.

 

To learn more about choosing the right type of metals for your specific stud welding process and the products we have available, contact Northland Fastening Systems at (651) 730-7770. You can request a quote online to get started with us today.

Spot Welding vs. The Stud Welding Process

Welding is one of the older manufacturing operations still used extensively throughout industries today, with the first types of forge welding dating back to the Bronze and Iron Ages in the Middle East and Europe. Today’s modern welding techniques vary greatly in their processes and results. Stud welding, for example, is a much different process than resistance welding, but each type of welding has its place in the manufacturing world.

 

When it comes to stud welding, industries from shipbuilding to food-grade equipment fabrication all value its benefits and capabilities. Not only does stud welding create a connection point stronger that the stud itself, it’s also a rapid fastening system with clean results.

 

No matter what industry you work in, you can count on Northland Fastening Systems to provide a complete supply of tools, studs, accessories, and everything else you might need for the stud welding process.

 

While stud welding is sometimes confused for spot welding, they are two very different operations. Spot welding actually falls into the category of resistance welding or resistance spot welding (RSW), whereas stud welding is an arc welding operation.

 

Spot Welding

Resistance spot welding uses heat to join metals together. That heat is generated by resistance to electrical current. The heat brings the two pieces of metal being joined together to a range where they can be connected with high-pressure systems. The metals technically never melt to a molten state during a spot-welding process. Because of this, spot welding is more like a forging process. The metals do not intermix in the same way they do during a stud welding operation. Spot welding has limited uses because it works well with few materials. Primarily, spot welding is used with low-carbon steel, but it can be used to form brittle connections with high-carbon steel and aluminum alloys.

 

Stud Welding

Stud welding uses a drawn arc or capacitor discharge (CD) arc to generate heat at the connection point. The metals used are heated to a molten state and the metal molecules fuse together to form a strong connection. Whether you’re working with drawn arc, CD, or short cycle stud welding, the high heat involved can be used to weld on a much broader range of surfaces than spot welding. Stud welding also doesn’t require the high-pressure equipment that spot welding does and can be used even when access to the reverse side of the base material cannot be accessed.

 

Overall, the stud welding process is a more flexible, efficient, and powerful choice for many production floors. To learn more about the capabilities of stud welding, contact Northland Fastening Systems at (651) 730-7770, or request a quote online to get started with us today.

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.

 

Factoring Resonance and Ballistics into Stud Welding Applications

As with any manufacturing operation used to build assemblies that will face daily functioning stress, the long-term effects of resonance and ballistics on stud welded connections must be taken into account. Stud welding is a highly versatile and widely used operation for a range of industries. Not only is it key in standard shipbuilding and the construction of most large-scale structures, it’s also relied upon for food-grade welding and electrical enclosures.

 

Those working with stud welding operations can count on Northland Fastening Systems for all their stud welding supplies. We provide stud welding tools for rent or purchase, studs in a comprehensive range of dimensions with custom sizing available, stud welding accessories, and the expertise of our own stud welding technicians.

 

When taking into account the effects that resonance and ballistics have on stud welding applications, how those effects manifest and to what degree they will impact a secure connection point depends on the industry and how stud welding was utilized. The following industries will see effects of resonance and ballistics on stud welding in various different ways.

 

Automotive: Stud welding is used in the fabrication of multiple automotive parts and in the full assembly of those parts. Cars, trucks, and other vehicles all face different sources of resonance and ballistics. This includes the basic resonance of road friction, operational harmonics of the engine and assemblies, braking, shifting gears, and the general vehicle operations. Other sources of resonance include weather and road conditions. Ballistic impacts on a vehicle can come from an accident and objects flying from other vehicles or kicking up from the road.

 

Structures: Stud welding is a critical tool for the composite construction used in many different structures, from bridges to multi-story buildings. These structures face significant resonance from weather impacts that can range from standard calm weather to severe storms. In addition, bridges are under constant resonance from traffic and the ballistics of flying objects. Other large structures built with stud welding that undergo weather-related resonance are water towers, cell towers, windmills, and more.

 

Ships: Shipbuilding was the original fabrication industry to utilize stud welding as an essential manufacturing operation. Today, stud welding is still a primary tool in the shipbuilding process for a wide variety of types of ships and boats. From small motor boats to cargo freighters, every water vessel faces different types of resonance. All undergo resonance from the water friction and currents, as well as ballistics from objects underwater. Large ships also face significant resonance from engines, passenger motion, and the shifting of cargo. In fact, some shipwrecks, like the wreck of the Edmond Fitzgerald, have been attributed to resonance and shifting cargo causing serious imbalances in the ship and the security of the welding.

 

To learn more about the effects of resonance and ballistics on stud welding strength and the supplies we provide, contact NFS at (651) 730-7770 or request a quote online.

Effects of Weather on Stud Welding

If you’re using stud welding as one of your key production operations, you’re one of thousands of manufacturers with a powerful tool that is both efficient and cost effective. Stud welding is a highly utilized fastening system that developed out of its use in shipbuilding to be part of fabrication settings in many industries, from food grade to the construction of bridges and other large-scale structures. At Northland Fastening Systems (NFS), you can find everything you need for successful stud welding processes, including tools for rent or purchase, studs in a comprehensive range of dimensions, accessories, and our own technicians’ expertise. Whether you’re working with drawn arc, capacitor discharge, or short cycle stud welding, we have the supplies that will help you get the job done.

While many operators are able to work in indoors or in otherwise enclosed conditions, making the questions of weather and other elements irrelevant, many other stud welders work at outdoor sites with exposure to wind, rain, and temperature fluctuations. These worksite elements are factors that must be taken into consideration before attempting to use stud welding as an effective fastening system. Specifically, moisture and temperature are the elements that most directly affect the quality of a weld, no matter what metals or welding operations are being used.

Moisture: The stud welding process is most directly affected by moisture. Rain, snow, and even humidity can, at the least, damage the quality of a connection point, and at the most, compromise worker safety. If the worksite is exposed to heavy precipitation of any kind without cover, workers should never attempt to weld. With very light precipitation or some cover, welding technicians can perform successful welds safely, but even slight moisture can change the chemical makeup of the weld. The relative moisture and dew point must be measured and compared to the requirement of the specific metal being welded together. Metals like aluminum need very dry conditions for successful welds, and all surfaces must be properly cleaned and otherwise prepped for a weld. Both relative moisture and dew points can change with temperature variations in the worksite.

Temperature: Because temperature changes can impact the moisture and dew point, it’s important to monitor the air, the electrode, and the metal temperatures during the stud welding process. In addition to affecting the moisture, certain temperatures are too low or too high to allow for a successful connection point. Generally speaking, the temperature of the weld surface should not be lower than 0ºF to perform a successful weld.

No matter what the moisture or temperature of the worksite and the weld surface is when in a suitable range, the surface should always be properly prepped and the welding tool should be correctly calibrated. All of these factors will determine the quality of the weld and the standards of worker safety.

To learn more about stud welding, contact Northland Fastening Systems at (651) 730-7770 or request a quote online.

Fastening Systems for Types of Electrical Enclosures

Stud welding is one of the most commonly used operations for manufacturing a broad range of electrical equipment, including the highly critical enclosures that delicate electronics need if they will be placed in a setting with harsh conditions. Because stud welding provides a strong connection with clean welds that don’t leave marks on the opposite side of the weld, it’s an ideal process for fabricating electrical enclosures that will hold up to a broad variety of conditions.

 

Electrical enclosures need to protect the equipment contained within from wind, rain, snow, ice, dust, UV light, and even seismic activity. Stud welding is the tool needed to build enclosures that will be reliable against the elements in the long-term. With Northland Fastening Systems, you can get all the supplies you need to use stud welding as one of your primary fastening systems.

 

While the purpose and general design of different electrical enclosures doesn’t vary greatly between boxes, there are key differences that make specific enclosures more suited to one environment over another. For many enclosures, NEMA ratings (National Electrical Manufacturers Association) will determine what environment it’s best suited for. NEMA ratings range from 1 to 13, with NEMA 1 being the least hardy electrical enclosure (commonly used indoors) and NEMA 13 enclosures capable of holding up to industrial grade contaminants.

 

Some examples of NEMA ratings include:

 

  • NEMA 3 enclosures are the most weather resistant, capable of withstanding wind, rain, and more. NEMA 3X enclosures are even resistant to salt water corrosion and are used in outdoor settings near shorelines and on ships.
  • NEMA 4 enclosures are fully water tight and can be used in areas with large quantities of water. 4X enclosures have added corrosion resistance as well as being watertight.
  • NEMA 6 enclosures can be fully submerged in water or oil. 6P can be fully submerged for longer periods of time.
  • NEMA 7 and 8 enclosures are used in hazardous conditions that will be exposed to gases including propane, ethylene, methane, butane, hydrogen, acetylene, and benzene.

 

While NEMA ratings cover a broad range of factors that enclosures built with stud weld fastening systems will face, the issue of seismic activity is not addressed. Instead, seismic rated enclosures have their own requirements. To meet seismic grade enclosure requirements, stud welding is a necessary operation to use. Seismic rated enclosures need heavy duty doors, full welding, and mounting hardware. The need for seismic rated enclosures depends on the zone where an enclosure will be installed. Of Zones 1-4, seismic enclosures are necessary in Zones 3 and 4 where seismic activity is heightened.

 

Whether you need to manufacture NEMA rated or seismic grade enclosures, NFS has the supplies you need including stud welding tools for rent or purchase, welding studs in a complete range of dimensions, and the expertise of our own welding technicians. Contact us at (651) 730-7770 or request a quote online today to get started with stud welding fastening systems.

What NOT to Do When Stud Welding

At Northland Fastening Systems (NFS), we understand the significance of quality in a weld. Not only does the strength of the weld depend on the quality of the stud welding process, quality practices also directly impact worker safety on a job site. Whether you’re working with drawn arc or CD stud welding tools, you can find quality and reliability with NFS supplies. We provide a comprehensive range of welding studs, including pins and bar anchors with custom options available. We also offer welding tools for rent or purchase, welding accessories, and the expertise of our own stud welding technicians. No matter how big or small your stud welding project is, you can get the job done with the help of NFS.

When it comes to achieving a quality weld, there are many technical aspects that are key to being successful, such as calibrating the welding unit and using the right metals. However, for non-automated welding operations, a large part of achieving a quality weld depends on the skills and performance of the welders themselves. Stud welding technicians can do many tasks right or wrong during a welding operation. The following are some of the basic “DON’TS” that welders should steer clear of if they want a quality stud connection point:

  1. Do not weld in an unventilated work site. No matter what type of welding process you’re using (stud welding or otherwise), the chemical changes that take place when metals are heated and bonded release fumes. These fumes can be toxic to inhale. That, in addition to ventilation helping to minorly improve the results of a weld, is why it’s critical to have a ventilated work site.
  2. Do not weld on an unstable surface, especially when working with stud welding. It’s important to weld on a clean, flat, and secure working surface. If you do have to weld on a painted or a slightly uneven surface, for example, take the necessary precautions to clamp, clean, and stabilize the surface as much as possible before welding. Unstable surfaces can cause injury to welders and result in a poor quality weld.
  3. Do not weld in an unsafe work site. An unsafe work site can include factors like water on the ground, nearby flammables, coiled cabling near the weld point, and even welding without the proper safety equipment. Not only does an unsafe work site risk severe injury to welders and anyone working in the vicinity, any danger to workers will most likely also play a role in sacrificing quality welds.
  4. Do not weld with unclean or unmaintained tools. Drawn arc and CD stud welding tools alike inevitably gather dust and contaminating particles over time. Because the damage that dust does to the welding tool itself is often minor, many welders are guilty of neglecting routine cleaning and maintenance. However, an unmaintained tool can be the reason for a poor quality weld. Preventing this potential problem is as simple as performing regular cleaning and maintenance checks.

To learn more about the “dos” and “don’ts” of stud welding, contact NFS at (651) 730-7770 or request a quote online today.

What Makes a Perfect Stud Weld?

Stud welding is a manufacturing operation that shows up in subtle ways throughout our world. From planes, trains, ships, and automobiles to bridges and even food-grade kitchen products, stud welding is a heavily utilized production tool that plays a part in making many items that we interact with daily. At Northland Fastening Systems (NFS), we support manufacturers relying on stud welding to get the job done. We provide comprehensive stud welding supplies, including welding tools for rent or purchase, studs in a range of dimensions with custom stud options available, stud welding accessories, and the skills and expertise of our own technicians. With our quality supplies and services, you can continually perform the perfect stud weld and fabricate with reliable, strong fastening systems.

 

If you are utilizing stud welding as a key manufacturing operation, it’s critical to understand what makes a perfect stud weld connection. If a weld is even slightly less than perfect, it’s not going to be effective, and it could cause some severe issues and potential safety concerns if put into a functional setting. To perform a perfect stud weld, there are three factors to take into account.

 

  1. Heat: Welding requires heat, but the temperature needed to get the perfect weld will vary depending on several factors. Typically, heat requirements depend on the kind of stud welding operation, the stud material and dimensions, the surface material, and any contaminants that might be on the surface, such as paint or rust. Calibrating the specific temperature needed to perform a perfect weld requires welders to be knowledgeable, experienced, and skilled. While the technical information concerning heat requirements is very detailed, it’s relatively simple to adjust heat specifications on most welding units.
  2. Pressure: The second factor involved in creating the perfect stud weld result is pressure. Even if you have the correct heat, if you have inaccurate pressure, the weld will be weakened. If you apply too much pressure, the weld could go too deeply into the base material and cause splattering, molten spread, misshapen welds, and other cosmetic defects. Additionally, too deep of a weld could create functional issues like cracking. Too light of a pressure application has its own issues and often creates a weld connection that isn’t fully formed. This can result in porous welds, brittleness, and cracks.
  3. Time: Finally, the time spent applying heat and pressure is equally important. Depending again on the weld type, materials, and other particle factors involved, the perfect stud weld will need to be applied for a specific time frame. Because the weld time varies within frames of fractions of seconds, it’s incredibly important to calibrate your tool to meet the necessary requirements. Failing to meet the right time requirements always means sacrificing the perfect stud weld.

 

To learn more about the other factors involved in creating a perfect stud weld, contact Northland Fastening Systems at (651) 730-7770 or request a quote online to get started with us 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.

The Strangest Buildings Made Possible with Stud Welding

Since its origins in shipbuilding during the turn of the century, stud welding has opened doors for thousands of construction projects unlike any others. Today, stud welding is used in a broad range of manufacturing operations, from sheet metal building to composite construction.

 

If you are working with stud welding fastening systems, you can count on Northland Fastening Systems for all your welding needs. Our skilled stud welding technicians offer expert advice and provide a comprehensive selection of welding studs, tools for rent and purchase, and stud welding accessories.

 

While stud welding is a common operation in many different industries, it has been used in many cases to build highly uncommon structures. Some of the strangest architectural endeavors were made possible thanks to the capabilities of stud welding. For example:

 

  • Guggenheim Museum: Located in Bilbao, Spain, the Guggenheim Museum was completed in 1997. The swooping titanium structures that make up the iconic avant-garde architectural look of the Guggenheim are held in place with multiple stud systems. This organic and deconstructivist style of architecture heralded in many other similar, yet unique structures.
  • Burj Khalifa: Dubai’s Burj Khalifa has been the tallest building in the world since its completion in 2009. The building reaches 2,722 feet at its tip and has a total of 163 floors. This massive skyscraper was built using stud welding in many different ways, including beam fastening and composite construction. In fact, stud welding allowed for the construction of all skyscrapers and many other building types since the first modern multi-story structures were built in the early 1900s.
  • Habitat 67: Finished in 1967 in Montreal, the model housing complex Habitat 67 offers 146 units in a unique format. The full structure of Habitat 67 is built with 354 concrete forms stacked and connected in various sections. The goal of this housing complex was to create the outdoor and indoor spaces of suburban neighborhoods within a confined city environment. Habitat 67 builders relied heavily on composite stud welding construction to complete this bold architectural project, and today it remains one of Montreal’s many interesting landmarks.
  • Eden Project: Located in Cornwall, England, the Eden Project is a large greenhouse complex inside multiple adjoining domes. These domes are made from polygonally connected steel tubing and inflated ethylene tetrafluoroethylene cells. The Eden Project is designed to emulate organic forms in reference to the thousands of protected plant species housed inside. Many components in the Eden Project were connected using stud welding fastening systems.

 

These are just a few examples of the many bold and unique construction projects that stud welding makes possible across the globe. To learn more about the stud welding supplies and tools we provide to a broad range of customers, contact Northland Fastening Systems today at (651) 730-7770 or request a quote online to get started with our team.