CAPACITOR DISCHARGE (CD) STUD WELDING PROCESS

Transcription

1 STUS (General Information) CAPACITOR ISCHARGE (C) STU WELING PROCESS 1. STU AGAINST WORK. 2. STORE ENERGY ISCHARGE THROUGH SPECIAL WEL TIMING TIP AN STU STARTS OWNWAR. 3. STU FORCE INTO MOLTEN METAL. 4. METAL SOLIIFIES AN WEL IS COMPLETE IN MILLISECONS. Capacitor ischarge (C) Stud Welding involves the same basic principles and metallurgical aspects as any other arc welding procedure. When the AVIS STUWELING weld gun is activated, a special precision weld tip initiates a controlled electric arc from the welder capacitor bank which melts the end of the stud and a portion of the base metal. The stud is held in place as the molten metal solidifies instantly accomplishing a high quality fusion weld. made to thin material without pronounced distortion, burn-through or reverse side discoloration. As long as one end of stud is designed for C welding, C studs can be manufactured in almost any shape. C Stud Welding is compatible with just about any weldable material, and permits the welding if dissimilar metals. C Stud Welding is generally used to weld smaller diameter studs to thin base metals, especially where reverse side marking is not permissible. Since the entire weld cycle is completed in milliseconds, welds can be 7-2

2 STUS (General Information) AVIS STU WELING C STU/BASE METAL COMBINATION WELING CAPABILITIES RECOMMENATIONS *Good: Generally full strength results, depending upon the combination of stud size and base metal. **Other materials, such as 7000 Series aluminum, titanium alloys, Inconel, etc, can be welded under specific conditions. C STU REVERSE-SIE MARKING LIMITATIONS The charts on the following page will be of help in determining the best combination of stud weld base 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 the AVIS STUWELING charts are based on optimum laboratory conditions. Even under optimum conditions, it is difficult to determine the precise point at which reverse-side marking will appear. Therefore, these charts should be used only as a guide. For further assistance contact the AVIS STU WELING Customer Service epartment. 7-3

3 STUS (General Information) HOW TO FIN THE OPTIMUM COMBINATION OF STU SIZE AN BASE METAL THICKNESS IN ORER TO PREVENT REVERSE-SIE MARKING BASE METAL THICKNESS.010".020".030" 1/ ".080".090" TO 28 1/4-20 UNACCEPTABLE ACCEPTABLE EXCELLENT 20 TO TO 28 MIL STEEL BASE METAL: Mild Steel STU: Mild Steel, Flanged or Small Flanged 14 GA. TO 25 GA GA. TO 25 GA BASE METAL: Stainless Steel STU: Stainless Steel, Flanged or Small Flanged 17 GA. TO 28 GA. 19 GA. TO 28 GA. 22 TO 28 1/ GA. TO 22 GA GA. TO 24 GA BASE METAL: Aluminum STU: Aluminum, Flanged or Small Flanged 19 GA. TO 24 GA GA. TO 26 GA TO ".060" 19 TO " 16 GA. TO 22 GA ".020" NOTE: Stud tip size can influence the degree of reverse-side marking..030".040".050".060".070".080".090" BASE METAL THICKNESS 7-4

4 STUS (General Information) C STU WEL INSPECTION (VISUAL) The illustrations and comments below will assist you in visually judging the quality of the weld. Full, even fillet all around stud. No or uneven fillet. Large crater-excessive metal expulsion, very shiny appearance. 7-5

5 STUS (General Information) C STU LOA STRENGTHS *These values should develop fastener tension to slightly less than yield point. 7-6

6 STUS (General Information) ( - ) ESTIMATE WEIGHTS OF THREAE STUS IN POUNS PER 1000 PIECES ESTIMATE WEIGHTS OF NON-THREAE STUS IN POUNS PER 1000 PIECES 7-7

7 C STUS FLANGE ANNULAR RING (NAVY) STU MIN. L R RL 1/8 3/ /16 3/4.175 CONFORMS TO MIL-S Type: VI Class: III NOM Copper coating is standard. CONFORMS TO MIL-S Type: VIII Class: III oes not apply to Stainless Steel. 1. Product Code... C F-AR 2. iameter Length...L 4. Material... MCAL Mushroom Cap (Aluminum) STU SIZE CAP PART NO. 3/16 MCAL NOTE: AR CAP is sold separately. Not a component part of stud. 7-8

8 C STUS FLANGE STU F MIN. L /4-20 5/ / Other grades available Copper plating is standard. oes not apply to Stainless. ANNEALING: BRASS ALLOY (lead free) std. Other alloys available Other alloys available 1. Product Code... C F 2. iameter

9 C STUS FLANGE/METRIC STU F MIN. L M3 X M4 X M5 X M6 X M8 X *All dimensions in millimeters Other grades available Copper plating is standard. oes not apply to Stainless. ANNEALING: BRASS ALLOY (lead free) std. Other alloys available Other alloys available 1. Product Code... C F 2. iameter M

10 C STUS SMALL FLANGE STU F MIN. L / / Other grades available Copper plating is standard. oes not apply to Stainless. ANNEALING: BRASS ALLOY (lead free) std. Other alloys available Other alloys available 1. Product Code...C SF 2. iameter

11 C STUS NON FLANGE STU MAX. B MIN. L / / Other grades available Copper plating is standard. oes not apply to Stainless. ANNEALING: BRASS ALLOY (lead free) std. Other alloys available Other alloys available 1. Product Code... C NF 2. iameter

12 C STUS FLANGE NO THREA STU /32 1/8 5/32 3/16 1/4 5/16 F MIN. L Other grades available Galvanized and Copper plating are available. oes not apply to Stainless. ANNEALING: BRASS ALLOY (lead free) std. Other alloys available Other alloys available 1. Product Code... C F-NT 2. iameter

13 C STUS SMALL FLANGE NO THREA STU Galvanized and Copper plating are available. 3/32 1/8 5/32 3/16 1/4 5/16 F MIN. L Other grades available oes not apply to Stainless. ANNEALING: BRASS ALLOY (lead free) std. Other alloys available Other alloys available 1. Product Code... C SF-NT 2. iameter

14 C STUS NON FLANGE NO THREA STU MIN. L 3/ /8 5/32 3/16 1/4 5/16 Other grades available Galvanized and Copper plating are available. oes not apply to Stainless. ANNEALING: BRASS ALLOY (lead free) std. Other alloys available Other alloys available 1. Product Code... C NF-NT 2. iameter

15 C STUS RAWN ARC STU Galvanized and Copper plating are available. F MIN. L / Other grades available oes not apply to Stainless. ANNEALING: BRASS ALLOY (lead free) std. Other alloys available Other alloys available 1. Product Code...C A 2. iameter

16 C STUS RAWN ARC NO THREA STU Galvanized and Copper plating are available. 3/32 1/8 5/32 3/16 1/4 F MIN. L Other grades available oes not apply to Stainless. ANNEALING: BRASS ALLOY (lead free) std. Other alloys available Other alloys available 1. Product Code...C A-NT 2. iameter

17 C STU BI-METALLIC STUS BMWP PIN BI-METALLIC STU Pin 10 GA (.135 ia.) Stainless Steel Pin 12 GA (.105 ia.) Stainless Steel Base Aluminum (5000 Series) WASHER: Self-locking washers are available in a variety of sizes, shapes and materials. 1. Product Code...BMWP 2. Length... L BMAR ANNULAR RING BI-METALLIC STU Pin Stainless Steel Base Aluminum (5000 Series) CAP: The cap for use with this stud is the WCN AR CAP annular ring cap. 1. Product Code... BMAR 2. Length... L BMNE NOTCHE EN BI-METALLIC STU Pin Stainless Steel Base Aluminum (5000 Series) WASHER: The washer for use with this stud is the WAK notched end key hole slotted washer. 1. Product Code... BMNE 2. Length... L 7-17

18 C STUS FLANGE-ACOUSTICAL HANGER (LAGGING STU) STU L F H HL W T / /8 5/16 1/ / /8 3/8 5/64 Copper plating is standard. ANNEALING: Other grades available oes not apply to Stainless. Other alloys available 1. Product Code...C F-AH 2. iameter

19 SPECIAL CAPACITOR ISCHARGE WEL STUS From an.060" diameter no-thread C stud to a 7/16" hex C stud, AVIS STU WELING can manufacture a special C stud to meet your precision fastening requirements. The illustrations below indicate just a few of the possible configurations in which C studs can be manufactured. These illustrations; however, do not represent any standard AVIS STU WELING instock product line. If you require a special configuration C stud for your application, please submit a sketch or drawing with dimensions and material requirements to AVIS STU WELING for a quote. 7-19