Stud Welding Procedures Training. Presented By Dan Beigel in cooperation with Texas Stud Weld and UFS QC.

Transcription

1 Stud Welding Procedures Training Presented By Dan Beigel in cooperation with Texas Stud Weld and UFS QC.

2 OVERVIEW Define - What is Stud Welding? Purpose - Why do we need Stud Welding? Training? Safety Setup Process Steps Inspection - What is a GOOD Weld? Visual Physical Summary Quiz Hands-On Training

3 Capacitor Discharge Stud Welding Capacitor Discharge (CD) Stud Welding is a semiautomatic process. With CD welding small diameter fasteners (¼" and under) Can be 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. Since the entire weld cycle is completed in several milliseconds, welds can be made to thin sheet without pronounced distortion, burnthrough or discoloration. CD welding permits stud welding of dissimilar metals.

4 PURPOSE OF STUD WELDING As it applies to Ultrafryer Systems, Inc. Why Do We Stud Welding? More economical than welding. Stud welding allows us to install studs in thin metals while preventing reverse side marking. Why do I need Training? 1. Safety - Insure operator awareness 2. Quality - Insure quality is maintained 3. Reliability - Insure minimal In Service defects 4. Consistency - Welds exhibit quality and reliability

5 Stud Welding Safety Precautions and Standards In any welding operation, it is the responsibility of the welder to observe certain safety rules to insure his/her personal safety and to protect those working near them. Always treat electricity with RESPECT. Under open circuit conditions, the welding machine output voltage can be dangerous. Never look directly at the electric arc during the weld process. Disconnect the main power line before checking or adjusting the gun or controller. DO NOT ATTEMPT ANY REPAIR OR ALTERATION TO THE GUN OR CONTROLLER. NOTIFY PLANT MAINTENANCE OF ANY PROBLEMS. Reference Standards ANSI Z Safety in Welding and Cutting AWG Publication A6, Recommended Safety Practices for Gas-Shield Arc Welding

6 Setup Procedures The set-up on a stud welding application refers to all the things the operator must do to weld a particular fastener. The operator must set the weld gun up and adjust the time and current settings on the power source. The diameter of the fastener, along with the base material and the weld stud material, all need to be considered.

7 Setup Cont..

8 Setup Cont... IMPORTANT Correct set-up for ALL Studs is 1/8 to 5/16 protrusion from the foot piece. 1. Obtain the proper accessories for the diameter of weld stud you will be using. The proper size collet must be installed in the stud gun. 2. A spark shield is installed in the hole in the foot piece, and held with set screws. The spark shield is used to protect the operator from splatter and to ensure that the weld stud is perpendicular to the weld surface. 3. Set the weld voltage on the power source to the approximate setting for that diameter weld stud.

9 The Capacitor Discharge Stud Welding Process Stud is Placed Against the Work Surface 2. Stored Energy is Discharged and Stud Starts Downward 3. Control Times Out and Stud Plunges Into Molten Steel 4. Metal Solidifies and Weld is Completed in Milliseconds. 5. Stud is securely attached to the work surface. RealOne Player Presentation

10 Stud Weld Visual Inspection Caused by using the collet extender!

11 Stud Weld Physical Inspection BEND TEST: By striking the weld stud with a hammer, or by sliding a length of pipe over the weld stud, the stud can be bent a minimum of 30 degrees away from its axis, or until failure occurs. Satisfactory welded studs should exhibit a complete 90 degree bend without failure.

12 PREVENTING REVERSE SIDE MARKING Metal Thickness 1/ GA to 25 GA 16 GA to 25 GA Fastener Size GA to 28 GA 19 GA to 28 GA to 25 Stainless Steel Base Metal Key Unacceptable Acceptable Excellent

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