What is stud welding and how does it work? The 12 most ... - dpiaca
What is stud welding and how does it work? The 12 most ... - dpiaca
What is stud welding and how does it work? The 12 most ... - dpiaca
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Time <strong>and</strong> cost savingsNew design potentialsUnsurpassed economyStud Welding<strong>What</strong> <strong>is</strong> <strong>stud</strong> <strong>welding</strong> <strong>and</strong> <strong>how</strong> <strong>does</strong> <strong>it</strong> <strong>work</strong>?<strong>The</strong> <strong>12</strong> <strong>most</strong> important questions <strong>and</strong> answers ...
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special ProcessesStud WeldingAdvantages ...In many areas <strong>stud</strong> <strong>welding</strong> <strong>is</strong> the <strong>most</strong> economic fastening methodfor components.If using thin plates, <strong>stud</strong> <strong>welding</strong> <strong>is</strong> often the only technical solution.W<strong>it</strong>h th<strong>is</strong> HBS information brochure we want to s<strong>how</strong> you theadvantages of our technology.After answering the <strong>12</strong> <strong>most</strong> important questions about<strong>stud</strong> <strong>welding</strong>, we provide you w<strong>it</strong>h an overview ofthe st<strong>and</strong>ard <strong>and</strong> HBS special processes.Have fun reading <strong>it</strong>![ 2 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special ProcessesTremendous time<strong>and</strong> cost savingsNo:drilling – punching – threading – gluingriveting – screwing – fin<strong>is</strong>hingNew designpotentialsÜÜÜÜÜÜVery low d<strong>is</strong>tortion by extremely short <strong>welding</strong> timeNo leaking caused by drilled holesHigh strengthOne-sided accessibil<strong>it</strong>y of the component <strong>is</strong> sufficientWeldable even onto very thin platesJoining of different materials <strong>is</strong> possibleUnsurpassedeconomyÜÜÜÜÜCan be automated to a very high degreeVery short <strong>welding</strong> time (1-990 ms), fast weld ratesFast <strong>and</strong> easy h<strong>and</strong>ling leads to high productiv<strong>it</strong>yNo marks on backside of coated or high alloyed platesLow prices for st<strong>and</strong>ard <strong>stud</strong>s[ 3 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special Processes<strong>The</strong> <strong>12</strong> <strong>most</strong> importantquestions <strong>and</strong> answers ...1. <strong>What</strong> <strong>is</strong><strong>stud</strong> <strong>welding</strong>?ÜThreaded <strong>stud</strong>s, pins, tapped pads, clips etc. arewelded by an arc w<strong>it</strong>hout add<strong>it</strong>ional material2. How <strong>does</strong><strong>stud</strong> <strong>welding</strong> <strong>work</strong>?ÜAn arc <strong>is</strong> ign<strong>it</strong>ed between the face of the <strong>stud</strong> <strong>and</strong> the surface of<strong>work</strong>piece; once both parts are melted, the <strong>stud</strong> <strong>is</strong> gently pressedagainst the <strong>work</strong>piece <strong>and</strong> than joined together[ 4 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special Processes3. <strong>What</strong> kind of processesare available?ÜÜCapac<strong>it</strong>or d<strong>is</strong>charge <strong>stud</strong> <strong>welding</strong> w<strong>it</strong>h tip ign<strong>it</strong>ion (TS) according toDIN 1) . Especially su<strong>it</strong>ed for <strong>welding</strong> on thin plates from about 0.6 mm m i n i -mum; plate thickness: 1/10 of <strong>stud</strong> diameter. Welding range: M3-M8 (M10)Drawn arc <strong>stud</strong> <strong>welding</strong> (DS) according to DIN 1) , process variations:drawn arc <strong>stud</strong> <strong>welding</strong> w<strong>it</strong>h ceramic ferrule or shielding gas; short cycledrawn arc <strong>stud</strong> <strong>welding</strong>; capac<strong>it</strong>or d<strong>is</strong>charge drawn arc <strong>stud</strong> <strong>welding</strong>.Especially su<strong>it</strong>ed for <strong>welding</strong> on thicker plates of 2 mm <strong>and</strong> above.Minimum plate thickness: 1/8 of <strong>stud</strong> diameter.Welding range: Ø 2-22 mm (M24)See page 10-11; HBS special processes see page <strong>12</strong>-144. Where <strong>is</strong><strong>stud</strong> <strong>welding</strong> used?ÜÜCapac<strong>it</strong>or d<strong>is</strong>charge <strong>stud</strong> <strong>welding</strong>: sheet metal<strong>work</strong>, electronicindustries, sw<strong>it</strong>chboard cabinets, laboratory <strong>and</strong> medical equipment,food industry, household appliances, communications engineering,vending machines, windows, glass constructions, insulation technology,industrial k<strong>it</strong>chens etc.Drawn arc <strong>stud</strong> <strong>welding</strong>: steel construction, mechanical engineering,shipbuilding, structural <strong>and</strong> civil engineering, power plants <strong>and</strong> combustionsystems, boiler <strong>and</strong> plant equipment, insulation <strong>and</strong> windows, buildings1) DIN EN ISO 14555[ 5 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special Processes5. How strong <strong>is</strong>the joint?ÜBecause the <strong>stud</strong> <strong>is</strong> joined w<strong>it</strong>h the <strong>work</strong>piece overthe whole surface of the <strong>stud</strong>, the strength of thejoint <strong>is</strong> even higher than the base material or the <strong>stud</strong>6. Which materialsare weldable?Generally materials of the same kind should be welded*Ü Capac<strong>it</strong>or d<strong>is</strong>charge <strong>stud</strong> <strong>welding</strong> according to DIN 1) 3) :steel (mild <strong>and</strong> alloyed steel), aluminum, brassÜ Drawn arc <strong>stud</strong> <strong>welding</strong> according to DIN 1) 2) :steel (mild <strong>and</strong> alloyed steel)* Other materials/combinations on request1)DIN EN ISO 14555 2) DIN EN ISO 13918 (formerly DIN 32500) 3) DIN EN ISO 13918 (formerly DIN 32501)[ 6 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special Processes7. Which <strong>stud</strong> diameter <strong>and</strong><strong>stud</strong> length can be welded?Ü Capac<strong>it</strong>or d<strong>is</strong>charge <strong>stud</strong> <strong>welding</strong> according to DIN 3) :M3-M8 (M10), Ø = 2-10 mmÜ Drawn arc <strong>stud</strong> <strong>welding</strong> according to DIN 2) :Ø = 2-22 mm (M24)Lengths: Ask for the HBS-brochure “Product Range – Welding Studs“8. Which <strong>stud</strong> shapesare available?ÜCapac<strong>it</strong>or d<strong>is</strong>charge <strong>stud</strong> <strong>welding</strong> according to DIN 3) : threaded<strong>stud</strong>s, pins, tapped pads, chr<strong>is</strong>tmas tree <strong>stud</strong>s, paint clearing<strong>stud</strong>s, grounding clips, cupped head pins, insulation pinsÜ Drawn arc <strong>stud</strong> <strong>welding</strong> according toDIN 2) : threaded <strong>stud</strong>s, pins, tapped pads,chr<strong>is</strong>tmas tree <strong>stud</strong>s, c o n c rete anchors,collar <strong>stud</strong>s, insulation pinsHBS also delivers custom madefasteners <strong>and</strong> <strong>stud</strong>sAsk for the H B S- b ro c h u re “Product Range – Welding Studs“2)DIN EN ISO 13918 (formerly DIN 32500)3)DIN EN ISO 13918 (formerly DIN 32501)[ 7 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special Processes9. How long <strong>does</strong> the<strong>welding</strong> process last?ÜÜCapac<strong>it</strong>or d<strong>is</strong>charge <strong>stud</strong> <strong>welding</strong>: 1-3 msDrawn arc <strong>stud</strong> <strong>welding</strong>: 5-990 ms10. Which qual<strong>it</strong>y of theplate surface <strong>is</strong> required?ÜÜ<strong>The</strong> surface of the plate must be electrically conductiveVarn<strong>is</strong>h, aluminium layers, scale, rust <strong>and</strong> plastic surfacesare to be removed. Check galvanized <strong>and</strong> oily plates fortheir weldabil<strong>it</strong>y11. How many <strong>stud</strong>s perminute can be welded?ÜÜManual <strong>stud</strong> feeding: 5-6 <strong>stud</strong>s per minute* (average)Automatic <strong>stud</strong> feeding: 20 <strong>stud</strong>s per minute* (average)* Production rate depends on application <strong>and</strong> type of HBS <strong>stud</strong>welders[ 8 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special Processes<strong>12</strong>. How to automate<strong>stud</strong> <strong>welding</strong>?ÜHBS delivers a wide product range: Starting w<strong>it</strong>h a h<strong>and</strong> held<strong>welding</strong> gun w<strong>it</strong>h automatic <strong>stud</strong> feeding, semi-automatic systems,up to fully automated <strong>stud</strong> <strong>welding</strong> un<strong>it</strong>s <strong>and</strong> robotic applications.Single source – by HBSAsk for our HBS-brochure “ProductRange – Automatic Stud Welding“[ 9 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special Processes<strong>The</strong> <strong>stud</strong> <strong>welding</strong>processes ...Capac<strong>it</strong>or d<strong>is</strong>charge <strong>stud</strong> <strong>welding</strong> w<strong>it</strong>htip ign<strong>it</strong>ion – CD1. <strong>The</strong> capac<strong>it</strong>ors are charged2. <strong>The</strong> CD-<strong>stud</strong> in the gun <strong>is</strong> moved by a spring to the <strong>work</strong>piece surface3. <strong>The</strong> tip touches the <strong>work</strong>piece <strong>and</strong> closes the electrical circu<strong>it</strong>. <strong>The</strong>rapidly increasing current melts the tip instantly <strong>and</strong> ign<strong>it</strong>es the arc4. Stud <strong>and</strong> <strong>work</strong>piece surface melt5. When the <strong>stud</strong> touches the <strong>work</strong>piece, the arc extingu<strong>is</strong>hes,the <strong>welding</strong> pools merge <strong>and</strong> solidifyAsk for our HBS-brochure “CD – Stud Welding Systems For CD-Welding“
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special ProcessesDrawn arc<strong>stud</strong> <strong>welding</strong> – ARC1. <strong>The</strong> <strong>stud</strong> <strong>is</strong> lifted up in the gun by a lifting device <strong>and</strong> a secondary arc(pilot arc) w<strong>it</strong>h low current <strong>is</strong> ign<strong>it</strong>ed2. <strong>The</strong>n the main arc <strong>is</strong> ign<strong>it</strong>ed between the tip of the <strong>stud</strong> <strong>and</strong> the<strong>work</strong>piece3. <strong>The</strong> surface of the <strong>stud</strong> <strong>and</strong> the <strong>work</strong>piece melt4. After the end of adjusted <strong>welding</strong> time the <strong>stud</strong><strong>is</strong> moved to the <strong>work</strong>piece; both <strong>welding</strong> poolsmerge. <strong>The</strong> power un<strong>it</strong> <strong>is</strong> sw<strong>it</strong>ched off;the weldpool solidifies <strong>and</strong> cools downAsk for our HBS-brochure “ARC – Stud WeldingSystems For ARC-Welding“[ 11 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special ProcessesAnd more: HBSspecialprocesses ...Stud <strong>welding</strong> byShort Cycle – SCDrawn arc short cycle <strong>stud</strong> <strong>welding</strong>Mains supply: 230 V single phase only2 sizes of power un<strong>it</strong>sÜÜSC 2400: idealy su<strong>it</strong>ed to fasten insulation pins (e.g. re f r a c t o ry insulation)SC 3200: chr<strong>is</strong>tmas tree <strong>stud</strong>s (e.g. cable fasteners)Ask for our HBS-brochure “SC – Stud Welding Systems For SC-Welding“Add<strong>it</strong>ional applications for SC 2400
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special ProcessesFastening of insulation material usingcupped head pins – ISOS p ecially designed power un<strong>it</strong> by HBS for <strong>welding</strong> cupped headpins to fasten insulation material (heat, cold, no<strong>is</strong>e <strong>and</strong> fire)ÜÜÜ<strong>The</strong> insulating mat <strong>is</strong> fastened in one stepVery cost effective fastening systemNo <strong>welding</strong> marks on backside(even on galvanized sheet) > 1 mmAsk for our HBS-brochure “ISO – Fastening Systems For<strong>The</strong> Insulation Market“Ask for HBS-“Catalogue High Temperature Insulation“[ 13 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special ProcessesNuts <strong>and</strong> pads <strong>welding</strong> by magneticrotated arc – MARCMARC <strong>welding</strong> <strong>is</strong> a variation of drawn arc <strong>stud</strong> <strong>welding</strong>.A magnetic field <strong>is</strong> rotating the arc <strong>and</strong> a weld pool on the entiresurface of the cylindrical pad <strong>is</strong> generated.Using th<strong>is</strong> procedure, you can weld on through-hole<strong>and</strong> dead end-hole applications, as well as on curved<strong>work</strong>piece surfaces.Ask for our HBS-brochure “Rotamat 800“[ 14 ]
HBS – Your partnerfor fastening methodsProduct range<strong>and</strong> qual<strong>it</strong>yÜÜÜÜReliable manual <strong>stud</strong> <strong>welding</strong> machinesCost efficient semi-automated machinesI n d u s t r i a l ,c o m p u t e r i z e d ,fully-autom. CNC-machinesComplete range of <strong>welding</strong> <strong>stud</strong>s <strong>and</strong> fastenersÜ HBS has been certified in 1994 according to DIN EN ISO 9001Research <strong>and</strong>developmentÜÜInnovative research <strong>and</strong> development departmentClose cooperation w<strong>it</strong>h several univers<strong>it</strong>ies <strong>and</strong> research inst<strong>it</strong>utesfor <strong>welding</strong> techniques <strong>and</strong> metallurgy to increase our leadershipin technology. As a result we are proud to hold numerous patents<strong>and</strong> awardsCompany profile <strong>and</strong>worldwide salesÜFounded in 1975, 50 employees. Our strength: development, design,assembly, own software for CNC-machinesÜ HBS sells <strong>it</strong>s products to more than 40 countries, export share: 50%[ 15 ]
HBS-Advantages HBS-Questions+Answers HBS-Processes HBS-Special ProcessesHBS Bolzenschweiß-Systeme GmbH & Co. KGFelix-Wankel-Straße 18 · D-85221 Dachau/GermanyPhone [49] (81 31) 5 11-0 · Fax [49] (81 31) 5 11-100e-mail: post@hbs-info.com · www.hbs-info.com
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