WHAT IS STUD WELDING?
WHAT IS STUD WELDING?Stud Welding is an arc welding process in which a stud or similar metal part can be end-joinedto a workpiece instantaneously. This stud welding process involves the same basic principlesand metallurgical aspects as any other arc welding procedure.The Process is as follows. The stud is placed (with a hand tool called the Weld Gun) against thebase metal, through the control of the stud welding equipment and the design of the stud; an arcis drawn which melts the base of the stud and a proportionate area of the base metal, the stud isthen forced into the molten pool and held in place until the metals re-solidify. This high qualityfusion weld is completed in milliseconds. There are two methods for accomplishing this studwelding process.CD STUD WELDINGARC STUD WELDING1. Stud against work2. Stored energy dischargedthrough weld tip & studstarts downward.1. Stud and ceramicferrule against work.2. Stud lifts andarc is drawn.3. Stud forced intomolten metal.4. Metal solidifies &weld complete inmilliseconds.3. Control times out& stud plunges intoMolten material.4. Metal solidifies &weld complete inmilliseconds.The two stud welding methods are called Capacitor discharge (CD) and ARC. The differencebetween these two methods involves the Power Source used to provide the welding current.Also, the design and application sequence of the stud varies slightly.The equipment required to stud weld is composed of the following: a direct current PowerSupply, a Controller, a Weld Gun, and Cables to tie the system components and base metaltogether. In most systems, the power supply and controller are combined as one componentcalled the “Welder”.www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-11-800-462-9353713-939-8903fax 713-939-9013
GENERAL SPECIFICATIONSCAPACITOR DISCHARGEMATERIALStandard in low carbon steel,302/304/305 stainless, and ll00,6061, & 5000 series aluminum.Brass and other grades of stainlesssteel are also availablePLATINGCopper plating is standard.Cadmium, Nickel, Zinc and otherplatings are available.ANNEALINGAll low carbon steel and stainlesssteel studs are annealed whererequired.THREADSUNC-2A is standard for externalthreads prior to plating and UNC2B for internal threads. Metricand other thread sizes areavailable.WELD BASEFlanged, small flanged, and nonflanged are available.STUD LENGTHCD studs have no appreciablelength reduction after welding.FERRULESDoes not apply to CD.ARCStandard in low carbon steel and302/304/305 stainless. Aluminum,monel, inconel, and other grades ofstainless steel are available.Cadmium to ASTM-A165 type TS,zinc to ASTM-B 633 (formerly A164) and other platings are available.Non-weldable plating is removedfrom the weld end to avoidcontamination of the weld.Low carbon steel can be annealed to amaximum of 75 Rockwell B andstainless steel to a maximum of 90Rockwell B.UNC-2A is standard for externalthreads prior to plating and UNC-2Bfor internal threads. Metric and otherthread sizes are available.1/4” dia. and over have solid flux.Diameters under 1/4” are standardpointed, and flux is optional.SUNBELT arc stud lengthdesignations are BEFORE WELD.AFTER WELD lengths are shown inthe table below.STUD DIAMETER3/16” thru 1/2”5/8” thru 7/8”7/8” and over1/8” wide ��All orders include ferrules when theyare required.www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-21-800-462-9353713-939-8903fax 713-939-9013
HOW CAN STUD WELDINGREDUCE COST?Stud Welding can reduce costs by saving labor and material where end joined componentsare required by speeding up design time and application rates, and preventing many commonsecondary operations. Bosses and spotfacing, counterboring, undercutting and manual filletwelding, soldering, drilling and tapping, riveting, inserts and special retainers are often totallyeliminated. Yet in most cases the welded joint is stronger than many of these traditionaljointing methods.A single operator, working with a single system, from just one side of the workpiece canattach many parts each minute.Other advantages with CD stud welding include attachment to very thin metals, no reverseside marking such as in prelaminated, painted, or plated parts and no excessive part heating orwarpage. ARC stud welding provides high fastener strength requiring less material forcomponent system integrity, and is usually not affected by minor contamination situationspresented in normal construction procedures.www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-31-800-462-9353713-939-8903fax 713-939-9013
THE ARC STUD WELDING PROCESS1. STUD AND CERAMICFERRULE AGAINST THEWORK PLATE.2. STUD LIFTS & ARC ISDRAWN.3. CONTROL TIMES OUT &STUD PLUNGES INTOMOLTEN STEEL.4. METAL SOLIDIFIES & WELDIS COMPLETED IN MILLISECONDS.ARC Stud Welding involves the same basic principles and metallurgical aspects as any other arcwelding procedure. The weld gun lifts the stud a short distance from the base metal and initiatesa controlled electric arc from the power source which melts the end of the stud and a portion ofthe base metal. The ceramic ferrule contains the molten metal into which the stud is thrustautomatically and a high quality fusion weld is accomplished. ARC Stud Welding is generallyused to weld larger diameter studs to thick base metals. ARC studs may be almost any shapeand there are literally hundreds, however, they must have one end of the stud designed for ARCwelding and must be made of weldable materials. Mild steel, stainless steel, and aluminum areapplicable materials for ARC stud welding.www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-41-800-462-9353713-939-8903fax 713-939-9013
ARC STUD WELDINGGENERAL INFORMATIONRECOMMENDED MINIMUM BASE METAL THICKNESSSTEELWITHOUT 0.0897130.1196110.14890.1870.2500.375STUD WELDBASE .8751.000ALUMINUMWITHOUT BACKUP WITH 70.1870.2500.1870.2500.250ARC STUD WELDER SELECTION GUIDESTUD WELDERPRO RC-500ARC-800ARC-1550ARC-2100MN/ASTUD WELD BASE DIAMETER IN INCHESUP TOUP TOUP TOUP TOUP TO1” .comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-51-800-462-9353713-939-8903fax 713-939-9013
CD AND ARC STUD WELD TESTING(PHYSICAL)BEND TEST: (See illustrations) Bystriking the stud with a hammer, or bysliding a length of pipe or tube over thestud, the stud can be bent a minimum of30 away from its axis, or until failureoccurs. Satisfactory welded studs shouldexhibit a complete 90 bend withoutfailure.TORQUE TEST: The stud may betorqued with conventional torqueequipment by applying torque until apredetermined torque or proof load isreached or until failure occurs.TENSILE TEST: The stud may be testedwith conventional tensile testing equipmentuntil a predetermined load is reached oruntil failure occurs.OTHER: The stud and weld can besubmitted to other conventional forms ofdestructive or non-destructive testing asspecifications may require.www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-61-800-462-9353713-939-8903fax 713-939-9013
WEIGHTS AND PACKAGINGCONCRETE 165-3/166-3/166-9/168-3/1610-3/16SHIPPING WEIGHT CHARTPOUNDSPER 46PIECESPER 010080150100POUNDSPER 7778718175696355625211798PCS. 506,7505,4004,0503,3752,7002,7002,1601,350900*LBS. 7011,4851,6741,4041,053882*Weight shown does not include the weight of a pallet (approx. 39 pounds)www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-71-800-462-9353713-939-8903fax 713-939-9013
WEIGHTS AND PACKAGINGSHEAR /49-1/4SHIPPING WEIGHT CHARTPOUNDSPER CESPER 1001008075605050100100757575505045858540POUNDSPER 56557631341511251397057678115017191PCS. 01350765765360*LBS. 015391809218713501539819*Weight shown does not include the weight of a pallet (approx. 39 pounds)www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-81-800-462-9353713-939-8903fax 713-939-9013
WEIGHTS AND PACKAGINGDEFORMED BAR ANCHORSDIAMETERSHIPPING WEIGHT CHARTBAR LENGTH10-1/812-1/818-1/824-1/8PCS. PER BOX150150150150LBS. PER ww.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-91-800-462-9353713-939-8903fax 713-939-9013
ARC STUDS WEIGHT CHARTS(STEEL)ESTIMATED WEIGHTS OF THREADED STUDS IN POUNDS PER 1000 0125.0170.0230.0350.0EACH ADD’L INCH11.017.025.034.046.070.0107.0“P” FERRULE1.82.83.14.55.910.821.9ESTIMATED WEIGHTS OF NO-THREAD STUDS IN POUNDS PER 1000 05624.040.070.0109.0156.5212.5278.0EACH .35.05.27.415.530.1“F” lding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-101-800-462-9353713-939-8903fax 713-939-9013
ARC ENGINEERING SPECIFICATIONSAND LOAD STRENGTHSThese basic specifications are typical values of mechanical properties of Sunbelt studs. Also shown are the chemicalproperties of low carbon steel. For actual material analysis and physical properties, Sunbelt will provide, upon request, adetailed material 7/16-141/2-135/8-113/4-107/8-91”-8SUGGESTED FASTENINGTORQUE (INCH 5915301919232828323440-ULTIMATE TENSILESTRENGTH 010200 16900 12800 ATE SHEAR 70040900-LCS (Low Carbon Steel): Chemical Properties: C-.23% Max.; P-.040% Max.; Mn-.90% Max.; S-.050% Max Mechanical Properties: Tensile Strength: 60,000 PSI Min.; Yield Strength: 50,000 PSI Min.; Elongation in twoinches: 20% Min. Mechanical Properties (Annealed): Tensile Strength: 50,000 PSI, Yield Strength: 35,000 PSI; Elongation in twoinches: 25%.HSS (High Strength Steel): Mechanical Properties: Tensile Strength: 120,000 PSI Min.304SS (Stainless Steel Type 302/304/305/316): Mechanical Properties: Tensile Strength: 85,000 PSI Min.; Yield strength: 40,000 PSI Min.; Elongation in twoinches: 45%. Mechanical Properties (Annealed): Tensile Strength: 80,000; Yield strength: 30,000 PSI Min.; Elongation in twoinches: 50%.5000SA (Aluminum Alloy – 5000 Series): Mechanical Properties: Tensile Strength: 42,000 PSI Min.; Yield Strength: 30,000 PSI Min.Disclaimer: The provided performance data is intended as guideline specifications & strengths only and is based on assumptions ofgeneral and reasonable use. Performance suitability for any specific application should be determined by the user.www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-111-800-462-9353713-939-8903fax 713-939-9013
MANUFACTURING DATATHREADSStandard threads are UNC-2A for male threads, UNC-2B for female. Some sizes are also stocked inUNF-2A and 2B sizes. Other thread classifications are available on special order. Wheneverpossible, all studs are thread rolled.PLATINGZinc plating is available according to ASTM-A 164-55-RS. Other plating materials are available onrequest. Plating is removed from the weld base to prevent contamination on all studs except 10Gauge pins.ANNEALINGSunbelt arc welding studs can be annealed to a maximum of 75 Rockwell B for low carbon steel; 90Rockwell B for stainless steel.FLUXExcept for some studs less than 5/16” diameter, all studs are solid fluxed at the center of the weldbase.FERRULESAll orders include ferrules when required. Ferrules are supplied with the studs and are not soldindividually.www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-121-800-462-9353713-939-8903fax 713-939-9013
ARC STUD WELDFILLET ACCOMMODATIONSTUD 0.8750.2181.1250.31290 COUNTERSINK RE OR COUNTERSINK METHODSWhen an arc stud is welded, a fillet forms around its base with the fillet dimensions being closelycontrolled by the design of the ferrule used. Since the diameter of the fillet is generally largerthan the diameter of the stud, some consideration is required in the design of mating parts.Counter bore and counter sink methods are commonly used. Dimensions will vary with studs andferrules. Additional methods of accommodating fillet include oversized clearance holes, use of agasket material around the fillet or use of a dog type construction.SEVERAL OPTIONAL METHODS OF FILLET ACCOMMODATION(A) OVERSIZECLEARANCE HOLE(B) GASKET MATERIAL(C) DOG CLAMPIF AN OVERSIZE FILLET DOES NOT MEETTHE APPLICATION:Welded studs designed with a reduced weld base areavailable so that the weld fillet does not exceed themaximum diameter of the fastener. This design is notrecommended if full fastener strength is important.www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-131-800-462-9353713-939-8903fax 713-939-9013
THE CAPACITOR DISCHARGESTUD WELDING PROCESS1. STUD AGAINST WORK.2. STORED ENERGY DISCHARGEDTHROUGH SPECIAL WELD“TIMING” TIP & STUD STARTSDOWNWARD.3. STUD FORCED INTO MOLTENMETAL.4. METAL SOLIDIFIES AND WELDCOMPLETED IN MILLISECONDS.Capacitor Discharge (CD) Stud Welding involves the same basic principles and metallurgicalaspects as any other arc welding procedure. When the weld gun is activated, a special precisionweld tip initiates a controlled electric arc from the welder capacitor bank, which melts the end ofthe stud and a portion of the base metal. The stud is held in place as the molten metal solidifiesinstantly accomplishing a high quality fusion weld. CD Stud Welding is generally used to weldsmaller diameter studs to thin base metals, especially where reverse side marking is notpermissible. Since the entire weld cycle is completed in milliseconds, welds can be made to thinmaterial without pronounced distortion, burn-through or reverse side discoloration. As long as oneend of the stud is designed for CD welding, CD studs can be manufactured in almost any shape.CD Stud Welding is compatible with just about any weldable material and permits the welding ofdissimilar metals.www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-141-800-462-9353713-939-8903fax 713-939-9013
CD STUD/BASE METALCOMBINATION WELDINGCAPABILITIESBASE WELD SURFACEMATERIALMILD STEEL:1006 through 1030MEDIUM CARBONSTEEL1030 through 1050GALVANIZED SHEETDUCT: OR DECKINGSTRUCTURAL STEELSTAINLESS STEEL: 405,410, 430, & 300 Seriesexcept 303LEAD FREE BRASS;ELECTROLYTICCOPPER; LEAD FREEROLLED COPPERMOST ALUMINUMALLOYS OF THE 1100,3000, 5000, 6000SERIES* *DIE CASTZINC ALLOYSMild Steel1008, 1010STUD MATERIALStainlessAluminum304, 3051100, 6061Brass70-30, ent--Excellent-Good*Good*ExcellentGood**Good: Generally full strength results, depending upon the combination of stud size and base metal. **Othermaterials, such as 7000 Series aluminum, titanium alloys, Inconel, etc. can be welded under specified conditions.CD STUD REVERSE-SIDE MARKING LIMITATIONSThe charts on the following page will be of help in determining the best combination of stud weldbase size and base metal thickness. The terms on the chart are defined as follows:EXCELLENT – No marking, excellent weld.ACCEPTABLE – Visible markings, excellent weld.UNACCEPTABLE – Unacceptable marking, base metal failure.It should be noted that these charts are based on optimum laboratory conditions. Even underoptimum conditions, it is difficult to determine the precise point at which reverse-side markingwill appear. Therefore, these charts should be used only as a guide.www.sunbeltstudwelding.comSunbelt Stud Welding, Inc.6381 Windfern RoadHouston, Texas 77040-49157-151-800-462-9353713-939-8903fax 713-939-9013
OPTIMUM COMB. STUD SIZE/BASEMETAL THICKNESS TO PREVENTREVERSE-SIDE MARKINGBase Metal Thickness.01” .02” .03” .04”1/4-2010-24Stud Diameter8-3216GA to 22GA19-256-3222-284-4022-281/4-2016 – 25 GA19 – 28 GA4-4022 -281/4-2015 GA to 22 GA10-244-40STAINLESS STEELBASE METAL: Sta
THE ARC STUD WELDING PROCESS 1. STUD AND CERAMIC 2. STUD LIFTS & ARC IS FERRULE AGAINST THE DRAWN. WORK PLATE. 3. CONTROL TIMES OUT & 4. METAL SOLIDIFIES & WELD STUD PLUNGES INTO IS COMPLETED IN MILLI-MOLTEN STEEL. SECONDS. ARC Stud Welding involves the same basic principles and metallurgical aspects as any other arc welding procedure.
STUD WELDING-THE PROCESS WHAT IS STUD WELDING ? TYPICAL STUD WELDING SYSTEM Stud Welding is a semi-automatic welding process in which a weld stud, pin, anchor or similar metal part can be end-joined to a parent metal surface instantaneously. This stud welding process involves the same basic principles and metallurgical aspects as any other
Stud Welding The stud is placed against the workplace. The stud is lifted off, while current is flowing, thus creating an arc. The arc melts the surfaces of stud and workpiece. The stud is plunged into the weld pool. A cross-sectional joint is achieved. Stud welding with ceramic ferrule Stud welding with shielding gas Short-cycle stud welding with
Sunbelt Stud Welding, Inc 6381 Windfern Road Houston, Texas 77040-4915 14-1 1-800-462-9353 713-939-8903 fax 713-939-9013 ARC STUD WELDING SYSTEMS . ARE complete stud welding systems which weld ARC studs using the ARC stud welding process.
13.3 Stud Welding Equipment Rent Stud Welders website www.completestudweld.com e-mail sales@completestudweld.com 32035 Creekside Drive, Cleveland, Ohio 44124 fax 216.378.0349 telephone 216.904.4008 COMPLEtE STUD WELDING Products Service Knowledge Integrity Complete Stud Welding has CD, ARC and Short Cycle stud welders available for rent to satisfy all applications.
weld area. ARC stud welding is generally used for studs over 1/4" in diameter or where heavier base metals are involved. "ARC" STUD WELDING PROCESS ARC STUD WELDING 1. Stud is placed against workpiece and weld gun trigger depressed 2. Stored energy is discharged through special tip 3. Weld gun forces stud into molten metal 4. Weld solidifies in miliseconds 1.
TRU‐WELD EQUIPMENT COMPANY . Capacitor Discharge (CD) stud welding is a form of welding in which the energy re ‐ quired for the welding process is derived from a bank of charged capacitors. . ing the tip of the weld stud, the pressure created by the movement of the stud to the base material by the stud gun fuses the stud to the base .
Studs, chucks and ceramic ferrules . The stud welding equipment is designed for the welding of weld studs using the arc pressure welding process. Keywords: Sunbelt Stud Welding, Inc. 6381 Windfern Road Houston, TX 77040 Phone: 713.939.8903 Toll Free: l.800.462.9353 Fax: 713.939.9013 .
Am I My Brother’s Keeper? The Analytic Group as a Space for Re-enacting and Treating Sibling Trauma Smadar Ashuach The thesis of this article, is that the analytic group is a place for a reliving and re-enactment of sibling relations. Psychoanalytic and group analytic writings about the issue of siblings will be surveyed. Juliet Mitchell’s theory of ‘sibling trauma’ and how it is .
