stud welding products StudPro 2500 User manual

OPERATION MANUAL
MODELS
TWE-250
TWE-321
TWE-375
TRU‐WELDEQUIPMENTCOMPANY
6400N.HONEYTOWNROAD
SMITHVILLE,OHIO44677
(330)669‐2773
MODELS
StudPro 2500
StudPro 3125
StudPro 3750
Downey, CA
9459 Washburn Rd.
Downey, CA 90242
Phone- 800.252.1919
Fax- 562.862.3022
Hayward, CA
2391 American Ave.
Hayward, CA 94545
Phone- 510.782.7883
Fax- 510.782.7918
Renton, WA
927 Thomas Ave. SW
Renton, WA 98057
Phone- 425.656.9787
Fax- 425.656.9786
Phoenix, AZ
3535 East Wier Ave., Ste. #4
Phoenix, AZ 85040
Phone- 602.305.9350
Fax- 602.305.4890
Toll free customer support: 1.800.252.1919

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CONTENTS
SectionDescriptionPages
1Introduction3
2ExternalFeatures4‐5
3Safety6‐8
4SetupandWelding9‐15
5TestingWeldSettings16
6InspectingTheWeld17
7CDStudGunViews18
8CDStudGunExplodedView19
9CDStudGunPartsList20
10CDControllerExplodedView21
11CDControllerPartsList22
1 Introducon 3
2 External Features 4-5
3 Safety 6-8
4 SetupandWelding 9-15
5 TesngWeldSengs 16-19
6 TypesofFractures 20
7 ArcBlowEect 21
8 CDStudGunExplodedView 22
9 InternalComponents 23-25
10 CDAccessoreis 26-29
11 TorqueBendingTest 30-31
12 CDGunSetUp’s 32-33

3
3
Thecompleterangeofthecapacitordischargeequipmentiscompact,portablestud
weldingequipment.Theunitsarespecificallydesignedtoenableasmalldiameter
rangeofferrousandnonferrousweldstudstobeweldedtolightgaugemetalmateri‐
alswithlittleornoreverse‐sidemarking.

Theequipmentconsistsofacontrolunit,aweldinghandgun,andallnecessaryinter‐
connectingcables.

THEPROCESS
CapacitorDischarge(CD)studweldingisaformofweldinginwhichtheenergyre‐
quiredfortheweldingprocessisderivedfromabankofchargedcapacitors.This
storedenergyisdischargedatthebaseofthespeciallydesignedCDstudanditfuses
thestudtothebasematerial.Thetimeoftheweldisdeterminedinsuchashortdu‐
rationthatnoburnthroughmarkingismadeonthefinishsideofthematerial.

CONTACT
IncontactCDwelding,thestudisplacedunderspringpressureonthematerialtobe
welded.Whenthecapacitorsaredischarged,thespecialtipoftheCDstudmeltsand
thespringpressureforcesthestudtofusewiththebasematerial.

GAP
IngapCDwelding,thestudisplacedontothematerialtobewelded.Asthestudgun
isengaged,thestudliftsfromthebasematerialandthenreturnstothepointofcon‐
tactatthetimeofthedischargeofthecapacitors.Asthecapacitorsdischarge,melt‐
ingthetipoftheweldstud,thepressurecreatedbythemovementofthestudtothe
basematerialbythestudgunfusesthestudtothebasematerial.
INTRODUCTION

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4
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FRONTPANEL
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
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1.WeldVoltageSelector‐rotatetochangetorequiredvoltage.
2.WeldingVoltageDigitalDisplay‐displaysselectedvoltage.
3.LEDLights‐Charging(capacitorsarebeingchargingtodesiredvoltage),Ready
(unitisreadytoweld),Reset(indicatesanerrorandunitshouldbeturnedoff).
4.WeldingGroundCableConnector(+)
5.StudGunControlConnector
6.WeldingStudGunCableConnector(‐)

EXTERNAL FEATURES
1
4
2
56
3
1
2
3
654

5
5
REARPANEL
1.On/OffSwitch
2.FuseHolder(10amp)
3.ACPowerCord
4.ManufacturerModelNumberandSerialNumberPlate


WARNING!
Thisunitoperatesfroma110VAC60Hertz@10ampcircuit.
Donotobstructtheventilationfan,asthismaycauseunittooverheat.
Donotremoveanyportionoftheunithousingwithoutfirstdisconnectingtheunit
fromthepowersupply.


EXTERNAL FEATURES
ON/OFFSwitch
15AmpFuse
PowerSupplyFan
ACCord
ON/OFF Switch
15Amp Fuse
Power Supply Fan
AC Cord

6
6

PROTECTYOURSELFANDOTHERS!
Readthesafetynoticesbeforeusingwelder.



ELECTRICAL
Noportionoftheoutercoveroftheweldingcontrollershouldberemovedbyany‐
oneotherthanqualifiedpersonnel.Alwaysdisconnecttheunitfromthemainpower
priortoremovingcover.
• Thisequipmentcontainsatransformerpowersupplysystem,whichisenergized
byACcurrentandtransformstheACtoDCcurrent.Duetopotentialdangerous
electricalinputandoutputtheequipmentmustbedisconnectedfromallincom‐
ingpowerwhenservicing.
• Capacitorsstoreelectricalenergy.Checkforresidualchargebeforeperforming
anymaintenance.
• Donotusefluidstocleanelectricalcomponentsasthesemaypenetratetheelec‐
tricalsystemandcauseshorts.

Connectionoftheunitintoservicemustbeinaccordancewiththesetupprocedures
asdetailedinthismanual.Operationofthisequipmentmustbeinaccordancewith
alllocal,regional,andnationalsafetycodes.

SAFETY

7
7

FIRE
Duringwelding,smallparticlesofhotmetalcanbeexpelled.Ensurethatnocombus‐
tiblematerialsareneartheweldingarea.




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
PERSONALSAFETY
Arcrayscanburnyoureyesandskin.Wearprotectiveclothingandeyeprotection
whenwelding.
Loudnoisesfromweldingcandamagehearing.Wearearplugsorotherprotective
gear,ifapplicable.
Fumesandgasesexpelledduringweldingcanbehazardoustoyourhealth.Make
sureweldingisdoneinawell‐ventilatedarea.
Hotmetalsplattercancausefiresandburns.Wearprotectiveclothing,freeofcom‐
bustiblematerials.Haveafireextinguishernearbyandknowhowtouseit.
MAINTENANCE
Allcablesmustbeinspectedregularlytoensurethatnodangerexistsfromwornor
damagedinsulationorunsafeelectricalconnections.Takespecialnotetothecables
nearthestudgun‐thisiswheremaximumwearoccurs.
Worncablesnotonlyproduceinconsistentwelds,butcanoverheatorspark.

SAFETY
FIRE HAZARD
FROM SPARKS

8
8

TRAINING
Useofthisequipmentmustbelimitedtoauthorizedpersonnelonly.Theymustbe
adequatelytrained,andhavereadandunderstoodeverythinginthismanual.The
manualmustbeavailabletooperatorsatalltimes.


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
INSTALLATION
Selectasitefortheequipmentwhichiscapableofsupportingtheweightofthe
equipment,whichisclearfromtrafficrouteswherepeoplemaytripovercables,or
theymaybedamagedbyotherequipmentorvehicles.
Donothangconnectingcablesoversharpedgesorhavenearheatsources.
DISPOSAL
Theequipment,initsentiretyorascomponents/partsmaybedisposedofasgeneral
industrialwasteorscrap.Noneofthecomponentsusedinthemanufacturingofthe
CDWeldersaretoxic,carcinogenic,orotherwiseharmfultoyourhealth.

SAFETY
AUTHORIZED
PERSONNEL ONLY

9
9
POWERINGUPTHEEQUIPMENT
Setuptheequipmentpowersupply(ControlUnit)andconnecttothemainpower,
makingcertainofthepropervoltagerequirementoftheparticularunit.
CapacitorDischarge(CD)unitsgenerallyrequire110VAC@60Hzincomingpower.
Refertothesafetyrecommendationsbeforepluggingthisunitin.

ON/OFFSwitch

Fuse

PowerCord(110VAC)

CONNECTINGTHEWELDINGLEADS
Connecttheweldinggroundcableintothe(+)terminalmountsocketonthefrontof
theweldingunit.
***NOTE‐thecableendplughasaflatwhichalignswithadotonthepanelmount
socket.Securetheconnectorintothepanelmountsocket,andthenturnitclockwise
untilitlocksintoproperposition.Failuretodosocouldresultindamagetothecon‐
nector.



GroundCableSocket
SET-UP AND WELDING
Ground Cable Socket
ON/OFF Switch
Fuse
Power Cord (110 VAC)

10
10
CONNECTINGTHEWELDINGLEADS
Connecttheweldingstudgunpowercableintothe(‐)terminalpanelmountsocket
(designatedbythegunsymbol)onthefrontoftheweldingunit.
***NOTE‐thecableendplughasaflatwhichalignswithadotonthepanelmount
socket.Securetheconnectorintothepanelmountsocket,andthenturnitclockwise
untilitlocksintoproperposition.Failuretodosocouldresultindamagetothecon‐
nector.



WeldingGunPowerConnector



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
WeldingGunControlCableConnector

Connecttheweldguncontrolcableintothecenterpanel2‐pinsocket.
**NOTE‐theplughasalargepinandasmallpinthatmatchthesocketontheunit.
Thisistopreventincorrectconnections.Pushtheplugfirmlyintothesocketand
twistclockwisetosecuretheplugintothecorrectposition.
SET-UP AND WELDING
Welding Gun Control Cable Connector
Welding Gun Power Connector

11
11
CONNECTINGTHEGROUNDCLAMP
Attachtheclampoftheweldinggroundleadtotheworkpiece.Priortosecuringthe
clamp,makecertainthatthecontactareaisfreeofrust,paint,grease,oranyother
impuritiestoensureagoodgroundconnection.



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
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

NOTE***Mostapplicationswillrequireonlyonegroundclamp,butcertainapplica‐
tionswillrequireanadditionaldualclamp.
SET-UP AND WELDING
13
CONNECTINGTHEGROUNDCLAMP
Attachtheclampoftheweldinggroundleadtotheworkpiece.Priortosecuringthe
clamp,makecertainthatthecontactareaisfreeofrust,paint,grease,oranyother
impuritiestoensureagoodgroundconnection.










NOTE***Mostapplicationswillrequireonlyonegroundclamp,butcertainapplica‐
tionswillrequireanadditionaldualclamp.

SET-UP AND WELDING

12
14
SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)
Thecolletisselectedtotheproperdiameterthatyouarewelding.
Therearethreestylesofcollets;
• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐
mineshowmuchofthestudisengagedinthecollet.
• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐
gagedispredetermined.
• StandardAdjustableChuckshaveanadjustableinternalscrewtomanuallyadjust
fortheengagementofthestud.
Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.

Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto
thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.
Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The
colletshouldbecenteredthroughtheopeningofthefootpiece.








Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐
let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”
ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset
screws.
SET-UP AND WELDING
FootPiece
Collet
LegPiece
12
SELECTINGTHEPROPERSTUDCOLLET(STUDHOLDER)
Thecolletisselectedtotheproperdiameterthatyouarewelding.
Therearethreestylesofcollets;
• The“B”colletwhichisatwo‐pieceassembly(colletandinsert).Theinsertdeter‐
mineshowmuchofthestudisengagedinthecollet.
• TheCI(ColletInsert)whichisasinglepartandtheamountofthestudthatisen‐
gagedispredetermined.
• StandardAdjustableChuckshaveanadjustableinternalscrewtomanuallyadjust
fortheengagementofthestud.
Thechoicebetweenthesesystemsisusuallyamatterofpersonalpreference.

Insertingtheselectedcolletintothestudgunisasimpletask.Placethecolletinto
thefrontholderofthestudgunandsetthelockingscrewstoholditinplace.
Afterinsertingthecollet,mountthetwolegsandfootpieceontothestudgun.The
colletshouldbecenteredthroughtheopeningofthefootpiece.






Whenthelegsandfootpieceareinplace,insertthestudtobeweldedintothecol‐
let.Adjustthelegandfootpiecebyslidingitintopositionuntilapproximately1/8”
ofthestudprotrudesfrombeyondthefootpiece.Locklegsinplacewiththeset
screws.
SET-UP AND WELDING
FootPiece
Collet
LegPiece

13
13
SELECTINGTHESPRINGLOAD
Theproperspringpre‐loadsettingonthestudgunwillvarydependingonthese‐
lectedapplication.Generalsrulesofapplicationwouldbe;mildsteelorstainless
steelusuallyinthe1to2range,dependingonthestuddiameterandthethicknessof
thebasematerial.Aluminumandothernonferrousmetalswouldrequiresettings
from3to5dependingonthediameterofthestudandbasematerialthickness.







Thisspringpre‐loadadjustmentismadebyturningthescrewinsertinthebackofthe
studgunwithascrewdriver.Onthebottomofthebackcapofthestudgunisthe
indicatornumbered1thru5,whichwillshowyouthetensionsettingduringthead‐
justment.
SET-UP AND WELDING
AdjustmentScrew
TensionIndicator
15
SELECTINGTHESPRINGLOAD
Theproperspringpre‐loadsettingonthestudgunwillvarydependingonthese‐
lectedapplication.Generalsrulesofapplicationwouldbe;mildsteelorstainless
steelusuallyinthe1to2range,dependingonthestuddiameterandthethicknessof
thebasematerial.Aluminumandothernonferrousmetalswouldrequiresettings
from3to5dependingonthediameterofthestudandbasematerialthickness.








Thisspringpre‐loadadjustmentismadebyturningthebackcapofthestudgun.On
thesideofthestudgunistheindicatornumbered1thru5,whichwillshowyouthe
tensionsettingduringtheadjustment.

SET-UP AND WELDING
AdjustmentCap
TensionIndicator
Locationofadjustment
onbackofthegun.

14
14
READYFORWELDING
Whenyouhavecompletedallofthepreviousstepstoprepareforwelding,including
connectingthestudgunandgroundcablestotheunit,attachingthegroundcable(s)
totheworkarea,settingupandadjustingthestudgunfortheselectedstuddiame‐
terandmaterial,youcannowpoweronthewelder.









ThecontrollerON/OFFswitchislocatedontherearoftheunitintheupperright
handcorner.Belowthisswitchisthe15ampfuseholderforthesystem.
SET-UP AND WELDING
ON/OFFSWITCH
FUSE
ON/OFF Switch
FUSE

15
15
VOLTAGESELECTION
Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto200VDC.
Thevoltageisdeterminedbythediameterofthestudandthebasematerial.




Approximatevoltagestaringpointsarelistedbelow.Finetuningthevoltagetomeet
yourrequirementforyourspecificapplicationisrecommended.










NOTE***whenweldingcupped‐headinsulationpins,settheDCVoltageto35voltsto
beginandincreaseasnecessary.AdjustthespringpressureontheCDgunbetween
#1and#3asnecessary.
SET-UP AND WELDING
DiameterVoltage(DC)
14ga.50‐75
12ga.75‐110
#8110‐130
#10125‐160
1/4”160‐190
DiameterVoltage(DC)
14ga.35‐50
12ga.50‐75
#875‐100
#10100‐120
1/4”120‐140
MODELTWE‐321&375
3/8”(TWE‐375)160‐200
5/16”140‐160
VoltageAdjustmentKnob
MODEL STUDPRO 2500
VOLTAGESELECTION
Selectingtherequiredweldvoltageisachievedbyturningtheselectorknob.The
voltagerangeisfrom35VDCto200VDC.
Thevoltageisdeterminedbythediameterofthestudandthebasematerial.




Approximatevoltagestaringpointsarelistedbelow.Finetuningthevoltagetomeet
yourrequirementforyourspecificapplicationisrecommended.










NOTE***whenweldingcupped‐headinsulationpins,settheDCVoltageto35voltsto
beginandincreaseasnecessary.AdjustthespringpressureontheCDgunbetween
#1and#3asnecessary.
SET-UP AND WELDING
DiameterVoltage(DC)
14ga.50‐75
12ga.75‐110
#8110‐130
#10125‐160
1/4”160‐190
DiameterVoltage(DC)
14ga.35‐50
12ga.50‐75
#875‐100
#10100‐120
1/4”120‐140
MODELTWE‐321&375
3/8”(TWE‐375)160‐200
5/16”140‐160
VoltageAdjustmentKnob
MODEL 3125 & 3750
(3750)
Voltage Adjustment Knob

16
18
TESTINGYOURSETTINGS
Whenyouhaveperformedallofthepresetsasdiscussedinthismanual,itisrecom‐
mendedthatyouperformseveraltestweldswiththesamediameterstudandbase
materialthatyouwillbeusing.Thiswillverifythatallofthesettingsarecorrectto
theresultsyoudesire.Weldingisdonebyplacingthestudintothecollet,andpress‐
ingthestudguntotheworkpiece,compressingthespring.Thisiswhythestudmust
protrudebeyondthefootpieceatleast1/8”.
Holdingthegunperpendiculartotheworkpiece,andaligningthestudtothedesired
positionontheworkpiece,pressdownsothatthefootpieceisflushwiththework
piece(springcompressed),anddepressthetrigger.












Whenremovingthestudgunfromtheweldedstud,alwaysliftthestudgunvertically
fromtheweldedstudinordertomaintainthepropertensionofthecollet.Spreading
thecolletwhenliftingthestudgunfromtheweldedstudwillshortenthelifeofthe
colletandwilleventuallycreateanundesirableweld.

TESTING WELD SETTINGS

17
17
INSPECTINGTHEWELD
Visuallyinspecttheweld.Agoodweldwillresultinanall‐aroundweld,withasmall
visibleamountofweldsurroundingtheflangeofthestud.Toomuchsplatterandthe
weldistoohot,lowerthevoltage.Nosplatterandtheweldistoocold,increasethe
voltage.
Ifyougetweldflashtoonesideofthestudasopposedtoanevenamountaround
thebaseoftheflange,thisiscalled“arcblow”,andcanbesolvedbyrepositioning
thegroundclamporusingadualgroundclamp.

Properweldedstudscanbetestedbyeithertorquingorbendingthestud.The
weldedflangeofthestudshouldstayinplaceusingeithermethod,eventhoughthe
threadedportionofthestudbreaks.Ifthebasematerialisverythin,thenafullslug,
thediameteroftheflangewillpullfromthebasemetalforaproperlyweldedstud.




CDStudWeldingSteps

SET-UP AND WELDING
TESTINGYOURSETTINGS
Whenyouhaveperformedallofthepresetsasdiscussedinthismanual,itisrecom‐
mendedthatyouperformseveraltestweldswiththesamediameterstudandbase
materialthatyouwillbeusing.Thiswillverifythatallofthesettingsarecorrectto
theresultsyoudesire.Weldingisdonebyplacingthestudintothecollet,andpress‐
ingthestudguntotheworkpiece,compressingthespring.Thisiswhythestudmust
protrudebeyondthefootpieceatleast1/8”.
Holdingthegunperpendiculartotheworkpiece,andaligningthestudtothedesired
positionontheworkpiece,pressdownsothatthefootpieceisflushwiththework
piece(springcompressed),anddepressthetrigger.










Whenremovingthestudgunfromtheweldedstud,alwaysliftthestudgunvertically
fromtheweldedstudinordertomaintainthepropertensionofthecollet.Spreading
thecolletwhenliftingthestudgunfromtheweldedstudwillshortenthelifeofthe
colletandwilleventuallycreateanundesirableweld.

TESTING WELD SETTINGS

18
18
CD 2301 Order No. BA 92-12-0231A Issue 05.01.10 31
5.8.1
Visual Inspection
A visual inspection must be carried out with each welding element.
Condition Possible cause Corrective actions
Good welded joint
Low spatters around the weld
without outer flaws
The weld pool forms a collar around
the flange of about 1 - 1,5 mm
- Correct parameters - None
Cold weld pool
Gap between flange and workpiece
- Heat input too low
- Plunging speed too low
- No sufficient backing of workpiece
- Increase charging voltage
- Adjust plunging speed correctly
- Provide sufficient backing
Hot weld pool
Many spatters around the weld
- Heat input too high
- Plunging speed too low
- Reduce charging voltage
- Increase plunging speed
One-sided weld pool
One-sided spatter collar
Weld pool came out on one side
- Arc blow effect
- Unsymmetric ground connection
- Welding gun put at an angle
- Take care for symmetrical ground
connection
- Put welding gun vertically to the workpiece
Visual Inspection
5 Stud Welding Procedure
5.8 Checking the Quality of the Weld
TESTINGYOURSETTINGS
Whenyouhaveperformedallofthepresetsasdiscussedinthismanual,itisrecom‐
mendedthatyouperformseveraltestweldswiththesamediameterstudandbase
materialthatyouwillbeusing.Thiswillverifythatallofthesettingsarecorrectto
theresultsyoudesire.Weldingisdonebyplacingthestudintothecollet,andpress‐
ingthestudguntotheworkpiece,compressingthespring.Thisiswhythestudmust
protrudebeyondthefootpieceatleast1/8”.
Holdingthegunperpendiculartotheworkpiece,andaligningthestudtothedesired
positionontheworkpiece,pressdownsothatthefootpieceisflushwiththework
piece(springcompressed),anddepressthetrigger.










Whenremovingthestudgunfromtheweldedstud,alwaysliftthestudgunvertically
fromtheweldedstudinordertomaintainthepropertensionofthecollet.Spreading
thecolletwhenliftingthestudgunfromtheweldedstudwillshortenthelifeofthe
colletandwilleventuallycreateanundesirableweld.
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TESTING WELD SETTINGS

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32 CD 2301 Order No. BA 92-12-0231A Issue 05.01.10
5.8.2 Bending Test
You can purchase from SWP a bending device with inserts for various diameters of the
welding elements.
The bending test serves as an easy work sample and as a check for the selected welding
parameters. The welded joint is stressed by bending in a non-defined way.
Bend the welding element with the bending device once by 30°.
Carry out the test in different directions.
The bending test is passed if a crack or a fracture of the welded zone does not occur.
Please note the instructions on fault recognition and corrective actions in chapter
5.
You don’t need to test all studs. It is sufficient to carry out stud
tests at random.
If the strength of the joint is inadequate, then:
check the setting of the stud welding unit
check whether the surface of welding element and base material are clean and
electrically conductive (must be free from scale, oil, paint, oxide layers)
grind off hardened work piece surfaces (e.g. roll hardening).
Check the piston of the welding gun for ease of movement.
5 Stud Welding Procedure
5.8 Checking the Quality of the Weld
TESTINGYOURSETTINGS
Whenyouhaveperformedallofthepresetsasdiscussedinthismanual,itisrecom‐
mendedthatyouperformseveraltestweldswiththesamediameterstudandbase
materialthatyouwillbeusing.Thiswillverifythatallofthesettingsarecorrectto
theresultsyoudesire.Weldingisdonebyplacingthestudintothecollet,andpress‐
ingthestudguntotheworkpiece,compressingthespring.Thisiswhythestudmust
protrudebeyondthefootpieceatleast1/8”.
Holdingthegunperpendiculartotheworkpiece,andaligningthestudtothedesired
positionontheworkpiece,pressdownsothatthefootpieceisflushwiththework
piece(springcompressed),anddepressthetrigger.
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Whenremovingthestudgunfromtheweldedstud,alwaysliftthestudgunvertically
fromtheweldedstudinordertomaintainthepropertensionofthecollet.Spreading
thecolletwhenliftingthestudgunfromtheweldedstudwillshortenthelifeofthe
colletandwilleventuallycreateanundesirableweld.
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TESTING WELD SETTINGS

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CD 2301 Order No. BA 92-12-0231A Issue 05.01.10 33
Type of fracture Possible cause Corrective actions
Base material buckling - Correct parameters - none
Fracture in the welding element
above flange
- Correct parameters - none
Fracture in the weld metal - Heat input too low
- Plunging speed too low
- Welding element/base material
combination not suitable
- Increase charging voltage
- Increase plunging speed
- Replace welding element or
workpiece
Backside deformation - Heat input too high
- Pressure too high
- Contact stud welding
not suitable
- Workpiece too thin
- Reduce charging voltage
- Reduce pressure
- Use gap stud welding instead of
contact stud welding
- Adapt thickness of workpiece
Bending Test
5 Stud Welding Procedure
5.8 Checking the Quality of the Weld
INSPECTINGTHEWELD
Visuallyinspecttheweld.Agoodweldwillresultinanall‐aroundweld,withasmall
visibleamountofweldsurroundingtheflangeofthestud.Toomuchsplatterandthe
weldistoohot,lowerthevoltage.Nosplatterandtheweldistoocold,increasethe
voltage.
Ifyougetweldflashtoonesideofthestudasopposedtoanevenamountaround
thebaseoftheflange,thisiscalled“arcblow”,andcanbesolvedbyrepositioning
thegroundclamporusingadualgroundclamp.

Properweldedstudscanbetestedbyeithertorquingorbendingthestud.The
weldedflangeofthestudshouldstayinplaceusingeithermethod,eventhoughthe
threadedportionofthestudbreaks.Ifthebasematerialisverythin,thenafullslug,
thediameteroftheflangewillpullfromthebasemetalforaproperlyweldedstud.
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CDStudWeldingSteps
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SET-UP AND WELDING
TYPES OF FRACTURES