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5 Studs Welding Precautions

Pulished on Mar. 18, 2023

Keep reading for more information on stud welding precautions.



1. Standing welding

For this welding position, the welding metal tends to flow to the lower side of the bolt when welding due to gravity, resulting in uneven welding angle formation. The larger the diameter of the bolt, the greater the impact. Generally speaking, for this reason, it is not recommended to weld bolts with a diameter of 10MM or more on vertical plates. To achieve a satisfactory weld angle formation, the shortest welding time is basically required. The smaller the diameter of the screw, the better for vertical welding. It must be remembered that special care must be taken to ensure that the bolt is perpendicular to the workpiece. On request, special foot attachments are available. Special care must be taken to keep the porcelain ring holder and the foot holder bolt holder clean.


2. Back welding

When back welding, it is necessary to wear a shield to protect the face and shoulders. Weld slag can cause damage. First of all, before welding the top part of the head plate, make a good welding setting under manual control. When welding manually, the weld metal flows from the bolts to the plate in small particles. For vertical welding, the melt flows against gravity. Therefore, for vertical welding, the shortest welding time is required to achieve the best results.

Special care should be taken to keep the porcelain ring jacket and the foot holder bolt jacket clean to prevent welding slag from falling on the workpiece surface.


3. Vertical welding or back welding when the welding gun adjustment

When using a torch with a shock absorber for standing or back welding, problems may be encountered. To prevent problems, remove the shock absorber. Remove the shock absorber, that is, remove the locking nut of the shock absorber, loosen the nut on the front cover to relax about 2mm. Then retighten the locking nut.


4. Use porcelain ring protection to weld screws shorter than 25mm in length.

The weld screw must be clamped in the groove of its clamp and must have sufficient length. The standard bolt holder has a 12mm deep groove and a maximum length of 13.5mm for the porcelain ring holder, so that if the bolt length is shorter than 25mm, it is difficult to get the correct bolt projection value, i.e. the bolt holder may hit the porcelain ring holder during welding and prevent the bolt from being pushed back to the plate correctly.

This problem can be solved by using a "shallow groove" jacket (only 6 mm deep) or, if the bolt to be used is very short, by using a special "break" type bolt. The bolts are 30 mm long in total and use a standard bolt jacket and a porcelain ring jacket. The bolt is easy to break at the required length from the welded end. After welding, the excess part of the bolt can be easily disconnected with pliers. Using this method, it is easy to weld very short bolts.


5. The minimum plate thickness for bolt welding

When using standard arc pulling equipment with porcelain ring protection, the minimum ratio of bolt diameter to plate thickness is 4:1 for plates thicker than 3 mm, and 3:1 for plates thicker than 1.5-3 mm. Due to the short welding cycle, it is possible to weld almost the same size bolt to a relatively thin plate using a short cycle system with or without air purge.

These ratios ensure that the plate is strong enough to support the bolt load and keep the plate free of distortion.

Occasionally, however, the welded bolts may exceed this ratio. In this case, a copper plate or water-cooled support is often placed under the weld area to support the plate to help dissipate heat quickly so that the heat-penetrated part does not distort.


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