Scribd
Upload
119 views

Lecture 7

Stud welding is a welding process where studs or bolts are welded to a metal surface. There are two main types of stud welding: stud arc welding and capacitor discharge stud welding. Stud arc welding uses electricity from a DC power source to create an arc between the stud and metal surface, melting them together. Capacitor discharge stud welding uses stored electrical energy from capacitors to create a brief, high-intensity arc. Stud welding provides benefits like short cycle times, minimal heat input and distortion, and not requiring drilling or tapping. However, it is limited to welding only one end of the stud and requires specialized equipment.

Uploaded by

Hijau Auliya Keramat Al-qadiry
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
119 views

Lecture 7

Stud welding is a welding process where studs or bolts are welded to a metal surface. There are two main types of stud welding: stud arc welding and capacitor discharge stud welding. Stud arc welding uses electricity from a DC power source to create an arc between the stud and metal surface, melting them together. Capacitor discharge stud welding uses stored electrical energy from capacitors to create a brief, high-intensity arc. Stud welding provides benefits like short cycle times, minimal heat input and distortion, and not requiring drilling or tapping. However, it is limited to welding only one end of the stud and requires specialized equipment.

Uploaded by

Hijau Auliya Keramat Al-qadiry
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 27

FWB 32503 ADVANCED WELDING PROCESS

STUD WELDING Lecture 7

3/23/2013

STUD WELDING
Form of spot welding where a
bolt or specially formed nut is welded onto another metal part. The bolts may be automatically fed into the spot welder. Weld nuts generally have a flange with small nubs that melt to form the weld. Studs have a necked down, unthreaded area for the same purpose.

3/23/2013

STUD WELDING
Stud Arc Welding process used 2 types of power source known as : 1. Stud Arc Welding 2. Capacitor Discharges Stud Welding

3/23/2013

ADVANTAGES OF STUD WELDING



Time cycle are very short Heat input on base metal very small Narrow HAZ Minimal Distortion Can be welded at any condition without affecting base member Drilling, tapping or riveting not required Light Safe cost Capacitor discharge power can welding dissimilar metal

3/23/2013

LIMITATION OF STUD WELDING Only one end o of stud can be welded


Limited on size and shape
Required disposable ceramic ferrule

Required flux
Required shielding gas Required high production power source
unit
3/23/2013

ARC STUD WELDING


Similar as MIG process Arc develop by dc arc between stud
(electrode) and plate (work) Welding current supplied by: 1. DC motor generator 2. DC transformer-rectifier Automated (complete quickly less then 1 sec) Use ceramic arc shield called ferulle
3/23/2013

PRINCIPLES OF OPERATION
2 steps of process:
- welding heat is develop with an arc between stud and plate. - two pieces are brought into intimate contact when the proper temperature reach.

3/23/2013

FLOW OF OPERATION
A fastener and ceramic ferrule are firmly placed against the work surface under spring tension.

Upon triggering, the weld gun automatically lifts the fastener from the base metal and initiates a controlled electric arc which melts the end of the fastener and a portion of the base metal.

3/23/2013

A ceramic arc shield concentrates the heat and retains the molten material in the weld area for maximum weld strength and reliability.

At the precise moment the fastener and the parent metal become molten, the fastener is automatically plunged into the work surface. The metal solidifies and a high quality fusion weld is completed.

3/23/2013

DESIGN
On fastener and support type ASW should attaching them. Compared to threaded stud, the base metal required less strength
with ASW. Arc welded from ASW may reduce the thickness of bosses. There is potential weight saving when using ASW. Range of stud steel from 3.2 32mm. Aluminum 3.2 13mm. Stainless steel 3.2 25mm. To develop full fastener strength, plate should be minimum of 1/3 weld base diameter. 1:5 is the minimum ratio of plate thickness to stud weld base diameter

3/23/2013

STUD
Stud material
1) low carbon steels, 2) stainless steels 3) aluminum
quantity of welding flux within or permanent affixed to the end of stud.

For low carbon and stainless steels stud required a

For aluminum stud required shielding gas, argon or


helium to prevent oxidization.

Stud have tip on the end to aid arc initiation


3/23/2013

STUD DESIGN

Most stud base are round For rectangular stud width to thickness ratio at the weld base should not exceed five. Stud design are limited in : 1) Weld can be made on only one end of a stud 2) The shape must be fit ferrule (arc shield) that fit the weld base. 3) The cross section of stud weld base must be within range 4) Stud size and shape must be permit chucking One important consideration in stud design is the recognize that some of length will be lost due to welding. Part of material from length reduction appears as flash in the form of a filler around the stud base.

3/23/2013

FERRULES
Made by ceramics material. Easy to remove by breaking them. Standard cylindrical in shape and flat across the bottom

for welding ti flat surface. Base of ferrule is serrated to vent gasses expelled from weld area. Internal shape design to form the expelled molten metal. Function: 1) concentrating the heat to weld area 2) restricting the flow of air into the area 3) confining the molten metal to weld area 4) prevent the charring of adjacent non-metallic material

3/23/2013

SPECIAL PROCESS TECHNIQUES


Gas arc
- use inert gas as shielding gas. - ferrule not required - suitable for steel and aluminum stud welding application (primary for aluminum) - limited to production type application
3/23/2013

SPECIAL PROCESS TECHNIQUES


Short cycle
- high weld current for very short time to minimize oxidization - limited to small stud (6.4mm) - shallow penetration

3/23/2013

EQUIPMENT
Gun Control unit Power source Duty cycle Power control unit Welding cable Automatic feed speed
3/23/2013

3/23/2013

APPLICATION
Automotive Boiler and building / bridge construction Farm and industrial equipment
manufacture Rail road Ship building Defense industrial
3/23/2013

CAPACITOR DISCHARGE STUD WELDING


A dc welding process where dc arc power
is produced by rapid discharge of stored electrical energy with pressure applied during following the electrical discharge Use an electro static storage system as power source which the weld energy is store in capacitor of high capacitance No ferrule or fluxing required
3/23/2013

The fastener is placed against the work piece. Most CD studs have a special tip which provides precise weld-time control, for consistent, automatic welds.

The weld gun is activated and stored energy is discharged through the fastener melting the full diameter of its base and a portion of the parent material.

3/23/2013

Spring-loading forces the fastener into the molten metal.

The fastener is held in place as the molten metal solidifies and instantly creates a high quality fusion weld

3/23/2013

PRINCIPLE ORF OPERATION


3 different type:
Initial contact method Initial gap method Drawn arc method

3/23/2013

INITIAL CONTACT METHOD


Special design projection on the weld end of

stud. Store energy is then discharge through the projection on the base of stud. Present high resistant and rapidly disintegrate from high current density. Pieces to be joint are being brought together by action of spring, weight, or air cylinder.

3/23/2013

INITIAL GAP METHOD


Stud is position of the work Stud is released and continuously moves

towards the work under gravity or spring loading Open circuit voltage is applied between the stud and the work High current flashes of the tips and initiated an arc. Stud plunges into the work

3/23/2013

DRAWN ARC METHOD



Similar to arc stud welding Not required a tip on the weld face An electronic control is used to sequence the operation Weld time is controlled by an electronic circuit unit Stud is positioned against the work The trigger on the stud welding gun is actuated. Low amperage pilot arc between them. Lifting coil is deenergize. The stud start to return to the work Welding capacitor are then discharge across the arc Spring action of the welding gun plunges the stud into molten metal.

3/23/2013

STUD LOCATION
Locating stud depend on several factor:
- accuracy and consistency of posityioning required - type of welding equipment to be use required rate production - geometry or shape of the workpiece

3/23/2013

APPLICATION
Aircraft and aerospace Appliances Building construction Maritime construction Metal furniture Stainless steel equipment Transportation
3/23/2013

You might also like