Arc stud welding

from Wikipedia, the free encyclopedia
Ted Nelson Stud Welding Gun (US Patent 2413189)

Arc stud welding (short form: stud welding , serial number 78 EN ISO 4063) is one of the arc pressure welding processes.

The aim of stud welding is the permanent connection of stud-shaped elements (e.g. threaded bolts, pins, sockets, hooks, eyes) with larger components (e.g. body panels, housings, radiators).

history

see history of welding

principle

In stud welding, an arc is ignited between one end face of the stud and the workpiece, both parts are locally melted and then joined under low contact pressure. Arc stud welding is divided according to the type of arc ignition into drawn arc stud welding and tip ignition stud welding. Both processes differ in the weld surface geometry of the studs, the process sequence, the equipment technology and partly in the area of ​​application. As with other arc welding processes, the so-called blowing effect can have a disruptive effect .

This article or section consists mainly of lists, which should be replaced by running text . Please help Wikipedia improve this. More about is here to find.

The most important welding parameters for arc stud welding are drawn arc ignition:

The most important welding parameters for arc stud welding are for tip ignition:

  • Charging voltage
  • capacity
  • Welding time
  • gap
  • Immersion speed / welding time

Procedure

This article or section consists mainly of lists, which should be replaced by running text . Please help Wikipedia improve this. More about is here to find.

Differentiation according to the type of ignition

Drawn arc stud welding

With drawn arc stud welding, the arc is generated by lifting the stud from the component while current is flowing.

Tip ignition stud welding

With tip ignition stud welding, the stud has a defined and tightly toleranced ignition tip on the side to be welded. The arc is ignited at this tip. This ignition tip melts like an explosion (bang) and evaporates to a small extent. The induction voltage created by the opening of the electric circuit ignites an arc which then covers the entire face of the bolt. The strong but short heat development produces a small weld pool in terms of area, which is sufficient to permanently connect the workpiece to the welding stud. Due to the low burn-in depth, due to the short welding time, it is possible to bring studs onto relatively thin materials (1.5–3 mm).

  • Splitting process: The bolt is moved towards the component from a certain height ( gap size ). The arc is ignited when the ignition tip comes into contact with the component.
  • Contact method: The stud is in contact with the component right from the start of welding. Otherwise the process is the same as for the splitting process.

Differentiation according to the type of weld pool protection

  • Stud welding with ceramic ring
  • Stud welding with shielding gas
  • Stud welding without weld pool protection

Differentiation according to the energy source

  • Stud welding with welding rectifier (transformer) or inverter power source
  • Capacitor discharge stud welding

Differentiation according to the welding time

  • Short-cycle stud welding
  • "Standard time" stud welding

Special process

Magnetic field stud welding (SRM)

Stud welding in a radially symmetrical magnetic field (SRM, Studwelding in Radially Symmetrical Magnetic Field ) corresponds to a further development of drawn arc stud welding and shielding gas. The arc is ignited in the middle of the bolt at the center point. Starting from the center, the arc is set in rotary motion by an external magnetic field. After thermal activation of the entire planar bolt end face, a stabilized arc pillar is created over the entire surface of the bolt cross section. The welding is finished as soon as a sufficient amount of melt has been generated. The melts of the bolt and the workpiece are connected to one another under low pressure. Due to the uniform melting of the stud and the base material through the magnetically stabilized arc, welds in a ratio of 1/10 (sheet thickness / stud diameter) are possible. The melting depth is only a few tenths of a millimeter. Negative influencing factors due to the blowing effect due to one-sided ground connection or mass accumulation can be compensated for by the method during the entire stud welding process. Further advantages are a very small heat-affected zone in the base material (60% less penetration into the base material), no obstructing weld bead and no weld spatter. Stud welding work in horizontal or overhead position (out of position) is made easier by the magnetic field.

Sleeve welding with magnetically moved (rotating) arc - MARC

The abbreviation MARC stands for Magnetic Rotating Arc . Welding with a magnetically moving arc extends the field of application of stud welding. The procedure is similar to drawn arc stud welding, but a rotating arc is used. The MARC process is an extremely economical connection technology. The advantages of MBL (MBP) welding (control of the heat input for tubular components through a magnetically moving arc) are combined with those of arc stud welding with drawn ignition (simple and inexpensive device technology, welding times in the millisecond range). The possibility of displacement of the arc column by an external magnetic field is the basis of the MARC procedure. The welding process is characterized by very short welding times, low heat load, low energy consumption, precise final dimensions and high economic efficiency. The rotation of the arc, and with it a concentrated and uniform input of energy over the welding surface, is achieved by a separate magnetic field in the welding gap. It enables the low-distortion and spatter-free welding of sleeves and nuts with an outer diameter of up to 30 mm, preferably made of high-alloy stainless steels with a flat welding surface up to a workpiece thickness of 5 mm. Gas- and pressure-tight welds are possible on perforated and non-perforated components.

Other ways of welding studs

Norms

The most important standards for stud welding are:

  • DIN EN ISO 14555 - Arc stud welding of metallic materials
  • DIN EN ISO 13918 - Studs and ceramic rings for arc stud welding
  • Leaflet DVS 0901 - Arc stud welding
  • Leaflet DVS 0902 - Drawn arc stud welding
  • Leaflet DVS 0903 - Arc stud welding with tip ignition
  • Leaflet DVS 0904 - Arc stud welding, tips for practice
  • Leaflet DVS 0967 - Calculation of stud welded connections

R. Trillmich; W. Welz - Stud welding, basics and application , DVS specialist book series welding technology, Volume 133, DVS Media GmbH, Düsseldorf, 2014

credentials

  1. ^ Patent US2413189 : Stud welding machine. Published on 1946 , inventor: Ted Nelson. ‌
  2. ↑ DIN EN ISO 4063: 2011-03 Welding and related processes - list of processes and serial numbers.

Web links