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GENERAL INFORMATION

 
Arc
Capacitor Discharge
MATERIAL Standard in low carbon steel and 18-8 stainless. Aluminum, monel, inconel, and other grades of stainless steel are available. Standard in low carbon steel, 18-8 stainless, and 1100, 6061, and 5000 series aluminum. Brass and other grades of stainless steel are also available.
PLATING Zinc to ASTM-B 633 (formerly A 164) and other platings are available. Non-weldable plating is removed from the weld end to avoid contamination of the weld. Copper plating is standard. Nickel, zinc, and other platings are available
ANNEALING Low carbon steel can be annealed to a maximum of 75 Rockwell B and stainless steel to a maximum of 90 Rockwell B. All low carbon steel and stainless steel studs are annealed where required.
THREADS UNC-2A is standard for external threads prior to plating and UNC-2B for internal threads. Metric and other thread sizes are available UNC-2A is standard for external threads prior to plating and UNC-2B for internal threads. Metric and other thread sizes are available
WELD BASE 1/4" diameter and over have solid flux. Diameters under 1/4" are standard pointed, and flux is optional. 3/8" and under weld base. Flanged, small-flanged and non-flanged are available.
FERRULES All orders include ferrules when they are required. Does not apply to CD.
 
 
Arc Stud
Diameter
Approx. Length
Reduction
3/16" Dia. Through 1/2" Dia. 1/8"
5/8" Dia. Through 7/8" Dia. 3/16"
1 Dia. and Over 1/4"
1/8" Wide Rectangulars 1/8"
Note:

Stud length reduction
does not apply to CD


  How Do Arc and CD Welding Differ?

Arc Stud Welding - The Process

Arc stud welding involves the same basic principles and metallurgical aspects as any other arc welding procedure, in that a controlled electric arc is used to melt the stud or electrode and a portion of the base metal. The stud is thrust automatically into the molten metal and a high quality fusion weld is accomplished where the weld is stronger than the stud itself. Stud welding is applicable to mild steel, stainless and aluminum.

Stud and ceramic ferrule against the work plate Stud lifts and arc is drawn
Stud and ceramic ferrule
are positioned
against the work plate
Stud lifts and
arc is drawn
Control times out; stud plunges into molten steel Metal solidifies; weld is completed in a split second
Control times out; stud
plunges into molten steel
Metal solidifies; weld is
completed in a split second


Welded fasteners or studs may be almost any size or type, and there are literally hundreds. However, they must be made of weldable materials, and one end of the fastener must be designed for welding. Conventional DC welding machines of all types may be used, but special power units designed specifically for stud welding are also available.

Advantages of Arc

  • Larger diameter Fasteners (up to 1-1/4")
  • Penetration of weld zone for structural-type strength
  • Welded metal fastening to heavier base materials
  • 230, 460, 575 volt sourcing
  • Ceramic Arc Shields or Ferrules used to maintain weld
  • CD Stud Welding - The Process

    Capacitor Discharge (CD) stud welding is a semi-automatic arc welding process. However, with CD welding small diameter fasteners (1/4" and under) are end welded to extremely thin gauge parent metal. The CD process operates on the principle of capacitor stored energy which is instantaneously discharged by the equipment system through a special weld "timing" tip.

    Stud against the work plate Stored energy discharged through special weld Timing Tip; stud starts downward
    Stud against the
    work plate
    Stored energy discharged
    through special weld
    "timing" tip;
    stud starts downward
    Stud forced into molten metal Metal solidifies; weld is completed in a split second
    Stud forced into
    molten metal
    Metal solidifies; weld is
    completed in a split second


    Since the entire weld cycle is completed in several milliseconds, welds can be made to thin sheet without pronounced distortion, burn-through or discoloration. CD welding permits stud welding of dissimilar metals.

    Advantages of CD

  • Welding to thin and sheet metal grade material
  • No reverse side marking
  • Up to 3/8" diameter fasteners
  • Only 115 volt power required
  • Up to 20 welds per minute
  • Welded metal fastening of dissimilar metals
  • For every design, for every purpose, there is one stud welded fastener best suited for the application at the lowest cost.


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