MASON Threaded Arc Stud
MASON Stud welding is a process by which a metal stud is joined to a metal workpiece by heating both parts with an arc of electricity. Compared with other welding and fastening processes, stud welding offers faster assembly with fewer steps. Weld studs and ferrules are available in a variety of shapes, sizes and materials.
Manufacturing companies today face the dilemma of increasing productivity while maintaining high product quality. For fastening metal parts, stud welding answers both sides of this dilemma. Compared with other welding and fastening processes, such as drilling and tapping, resistance welding, hand welding or clinch fastening, stud welding can be done faster with fewer steps. With no predrilling, punching or riveting required, the process yields significant productivity improvements and cost savings. At the same time, stud welding provides a high-quality attachment point that is secure and resists breaking or loosening.
MASON Arc Stud Welding
MASON Arc stud welding is a highly reliable fastening method for a wide variety of applications. The process can quickly weld almost any size or configuration of a metal stud to a workpiece, with maximum weld penetration and reliability.
MASON Arc stud welding creates strong, one-sided welds on base metals as thin as 1.5mm. It produces welds in as little as 0.06 seconds. The process requires a DC power supply to create the arc; a stud welding gun; metal fasteners; and in some cases, ferrules.
There are common techniques of MASON arc stud welding:
- drawn arc stud welding
- short cycle arc stud welding.
In the drawn arc technique, the stud is loaded into the chuck of the welding gun, and a ferrule (a disposable ceramic shield that contains the molten pool of metal) is placed over the end. The gun is placed against the workpiece. When the trigger is pressed, the DC power supply sends a signal that energizes the gun’s internal lift mechanism, lifting the stud and drawing the pilot arc. The pilot arc establishes a path for the weld current, which initiates after the pilot arc.
Upon completion of the correct arcing time, which is proportional to the square area of the surface being melted, the lift mechanism is de-energized. This causes the stud to plunge into the molten pool of metal. A plunge dampener is often used on larger studs to decelerate the stud’s movement onto the molten pool. This minimizes splash. As the stud and the base metal join, the metal begins to solidify and the weld is created. The gun is lifted, and the ferrule is discarded.
The drawn arc technique uses flux embedded in the stud to cleanse the metal surface during the weld. During arcing, the flux is vaporized and reacts with the contaminating elements in the atmosphere to keep the weld zone clean.
The short cycle arc technique is much like a drawn arc, except that it uses no flux load or ferrule. This technique offers the shortest welding times of the arc stud welding techniques. It is characterized by high currents and short weld times. While it may be suitable for many high-volume applications, it can produce porous welds and should therefore be selected when speed and cost are a priority over weld strength. The short weld times minimize the effects of porosity, while the high current maintains the needed energy.
MASON Arc Stud Welding Advantages
MASON Arc stud welding provides excellent welding success under a broad range of conditions. It produces a full cross-sectional weld, forming a bond that is stronger than the surrounding metal.
MASON Arc stud welding produces a strong, one-sided weld. The welds are vibration-proof and resist breaking, loosening or weakening. In applications where quality is measured in part by attractive appearance, MASON arc stud welding offers excellent cosmetic appeal because the reverse side is not marred. Finally, because MASON arc stud welding is a one-sided fastening process, it gives engineers greater design versatility.
Compared with other fastening processes, MASON arc stud welding is faster and easier. Each weld is achieved in less than a second, and the process requires access to only one side. Arc stud welding eliminates punching, drilling, tapping and riveting. With special techniques, it can be performed on painted surfaces, eliminating the need for grinding and recoating.
Labor costs are dramatically reduced with arc stud welding because through-hole preparation is eliminated and the process can be completed by a single worker. Often, an expensive, odd-shaped piece can be duplicated inexpensively by welding several studs to a simple stock shape to form a metal fabrication.
Item No.: MASONARCSTUD
Use: Steel Fastening
Type: Steel Fastening
Type of fixing: Stud Welding