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Summary of Contents for Miller Arc Stud Welding Fundamentals
- Page 1 003 338B July 2005 Arc Stud Welding Fundamentals Visit our website at www.MillerWelds.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1. -
Page 3: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. - Page 4 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.
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Page 5: Additional Symbols For Installation, Operation, And Maintenance
D Read Owner’s Manual before using or servic- support unit. ing unit. D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement long enough to extend beyond opposite side of parts. unit. -
Page 6: Principal Safety Standards
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard... -
Page 7: Section 2 − Arc Stud Welding (Sw) Guidelines
SECTION 2 − ARC STUD WELDING (SW) GUIDELINES 2-1. Process Description Arc stud welding (SW) is a welding process in which a metal fastener (weld stud) is joined to a workpiece. This process is generally referred to as stud welding. The metal fastener is joined under pressure once sufficiently heated with an electric arc. -
Page 8: Arc Stud Welding System
2-4. Arc Stud Welding System 804 157-A Constant Current (CC) Workpiece (Positive) Y Turn off power before connecting to weld output terminals. Ground Cable and Clamp 10 Weld Cable to Gun Power Source Stud Gun (Negative) 11 Control Cable 2-5. Power Source The typical power source for stud welding should have the following characteristics: D Constant Current (CC) -
Page 9: Volt/Ampere Curve - Constant Current (Cc) Power Source
NOTE The charts in (Sections2-7 and 2-8) show the voltage/amperage output and duty cycle of a stud welding power source that uses an external device for setting amperage and time. 2-7. Volt/Ampere Curve - Constant Current (CC) Power Source Max. Min. -
Page 10: Arc Stud Welding Guns
2-9. Arc Stud Welding Guns There are two basic arc stud welding guns available: D Portable, pistol grip configuration, which is used for hand-held or manual operation. D Fixed, production gun, which is usually mounted on a positioning device and is usually incorporated with an auto- matic fastener loading system. -
Page 11: Selecting Cable Length And Size
2-11. Selecting Cable Length and Size Weld cable length and size are very important. A power source is often penalized by the use of too small a cable or too long a cable system. The following chart will serve as a guide to selecting cable size and lengths in relation to the stud diameter and approximate amperage. -
Page 12: Section 3 − Stud Welding Process
SECTION 3 − STUD WELDING PROCESS 3-1. Stud Welding Sequence Welding sequence of control unit and process is broken down into four steps as shown below. Chuck Stud Ferrule Gun is properely Trigger is pressed and the After arcing is complete, Gun is withdrawn positioned and main stud lifts off the work. -
Page 13: The Welding Stud
3-3. The Welding Stud Welding grade studs are made of most commercially used metals, and normally range in diameters from 1/8 in (3.2 mm) to 1-1/4 in (31.8 mm) with lengths as required. In addition to straight threaded or unthreaded studs, it is possible to obtain a wide variety of shapes and sizes. -
Page 14: Stud Specification Chart
3-6. Stud Specification Chart The stud manufacturer’s catalogs will list the characteristics and dimensions of the various studs available. When set- ting up the welding parameters, the diameter (where contact is made to work) should be used as the determining factor for amperage and time setting. -
Page 15: Section 4 − Weld Inspection/Troubleshooting
SECTION 4 − WELD INSPECTION/TROUBLESHOOTING 4-1. Inspecting Welded Studs Inspect studs visually or by me- chanical testing. Problem - Poor weld Plunge of stud too short or high amperage. Remedy - Ensure that stud ex- tends 3/32 in to 3/16 in beyond the ferrule. -
Page 16: Performing Aws Bend Test
4-2. Performing AWS Bend Test Mechanical testing can be done to determine the strength of the welding area. This test should be performed when setting up parameters to assure a sound weld is being made. 30° 804 159-A The AWS Structural Welding Code D1.1-72 states: “Each welding unit before use in production shall be used to weld two stud or shear connectors to separate material in the same general position (flat, vertical, overhead, sloping) and of similar thickness. -
Page 17: Performing Aws Torque Test
4-3. Performing AWS Torque Test Studs that are torqued to destruc- tion without failure in the weld are considered qualified. Stud Washer Weld Area Member Sleeve Steel Nut 804 160-A NOTE Dimensions are appropriate to the size of the stud. Threads of the stud shall be clean and free of lubricant other than for the residue of cutting oil. - Page 18 Notes...
- Page 19 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in)
- Page 20 Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters − United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 www.MillerWelds.com © PRINTED IN USA 2005 Miller Electric Mfg. Co. 1/05...
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