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Traditional Fixing A Fastening:

Pressed InsertsInserts can work loose, crackpaint,and leave stains.Holes need to be punched thendeburred in parent materialweakening it - the reverse side isnot always left flat,and the insertis visible and unsightly.The resulting joint cannot alwaysbe guaranteed leak-proof.

Drilling & ToppingDrilling & Tapping ate very slowprocesses, requiring thickerparent matefial to achieve fulljoint strength.Drills and taps get broken andfasteners can vibrate loose.Through drilled holes needsealing and blind holes needclearing out.

Bock lUeldingBack

'Welding is a slow; messy

and inaccurate process.Holes are required, into which thefastener must be preciselypositioned.The biggest disadvantage ishaving to grind or polish offexcess matefial or burn marks onthe reverse side.

Through BoltingThrough Bolting is not tamper-proof, and is a cumbersome andslow pfocess requiring twohanded assembly with accessfrom both sides.Holes weaken the parentmaterial and leakage stains fromthe unsightly bolt heads arecommon.

Projection ond Resistonce tUeldingmeans taking a component to fixedequipment, replacing electrodes, andhigh power consumption costs.Soldering ond Brozing requiresclamping and causes distortion.Riveting is untidy, irreversible,requires.holes and works loose.All of these processes are slow,unsightly, require reverse access andneed cleaning and finishing.

S tu d,ut e I ding S au e s Tirn € :

tltt+ g*, I i+r + l rlx g:l hi'r $4iii f rfi fliiStudwelding replaced inserts onthese applications, resulting infaster production and strongerjoints.Thinner sheet could now beused. and with no feversemarking.Corrosion was eliminated asmoisture ingress was prevented.

$te*" g:s $ *;n c;; Li:'r eg Hil ru $ { $ * gg d$e'"fli,,r.r g":r g;* * * r 41Studwelding allowed thismanufactufer to speed upproduction considerably.Previously he had to leak testevery through drilled and tappedhole. An alternative solution ofusing thicker flanges would haveresulted in additional time andcost implications.

$}iirt+ g* fu;:u r* I +': rll,5 $'i,.$+rr * i'+ +#$ *:; ff +$ $ * g,pHere production increasedtenfold when studweldingreplaced a backwelding process.Vith no need to grind the topsurface flat and polish off excessmatefial and burn marks, timesaved was significant rejectcomponents wefe eliminatedwith additional cost savings.

$'4;r.;r-fir$+;r+*ir"lr'6"i{fr tr+.*lr+,+rg$**i$rm$f:$r.*ggOne component became tampef-proof, a clean design was thebiggest benefit on another.On a third part, the gauge wasreduce d and leakage wasprevented. Finally studweldingsolved the problem of loose boltsand inaccessibility to the bolthead after assembly.

fid'n,pi+:ri+ir':r+,,-tr ftlr*;-t:t:,r;{i+;lc'r4* $.$,.fi.*i$+:.Fi+"*+tremoved a bottleneck by not havingto take the biggest component to alarge resistance welding machine.ffd-*,9*;E+*,'i:$+'r..p fii*+i+$rrit.lglg cured acorrosion problem caused by solderflux. Some components which werepreviously brazed sustaineddamage because of the long heatcycle - studwelding eradicated this.

Studutelding Deliuers Reliability:

There are thfee types of studv/elding: capaciror Dischafge (cD), shoft cycle (sc) and Dfawn Afc (DA).They are complementary and should not be regarded as alternatiyes. with each method, a wito itua is held in a handtool -or pfoduction head - then presented squarely to the workpiece. The processes work as follows:

(D M2.s ro Mro oEnergy is stored in a bank of capacitorscharged to a pre-set voltage determinedby type of stud and parent material.'When

triggered, energy discharges as ahigh current pulse, melting the pip toproduce aflarc.

Spring pressure forges the stud onto themolten surface to ensure complete fusionacfoss the flange.'Weld

duration: Under 4 milliseconds.

SC frne.s to rvlg @A transformer rectifier supplies a fixedcuffent powef soufce. Triggeringproduces a pilot arc and the stud lifts to apre-set height.The main arc melts the end of the stud,producing a molten pool in the parentmaterial.Return spring pressllre then forges thestud into the pool. Using a shrouding gasreduces weld spatter especially withstainless steel.

Nfeld duration: 10 to 100 milliseconds.

DR M5 to Mz4 aCurrent level, and duration, aredetermined by the stud diameter.Triggering produces a pilot arc and thestud lifts to a pre-set height.The main arc melts the end of the stud,proclucing a molten pool in the material.

Return spring pressure then fbrges thestud into the pool. A ceramic ferrulecontains and shapes the weld fillet, thisarc shield is not re-usable.

Weld duration: 100 to 1000 milliseconds.

Although some cross-overs occur, the table below should guide you to select the right process:

CD is icleal fbr thin gauge.colcl rol lecl she ct w-herefc\ erse m:Lrking cr:rn berninimisccl, or cracl icatecl.Pe ncrtr:r . t ion into then'orkpicce is minimal.

For CD the sheet can be as thin as 0.7mm.Mild Steei, Stainless Steel, AiuminiumAlloy, Pure Aluminiurn & Leacl Free Brass.Sheet surface should be clean and flatStud welcl end must have precise pipand cone.

CD controilers arelightweight & handpotable. Lower costthan SC & DA.Single phase 230/770volt 50H2.

Low- crost stucls - Lor,' cost ec1_ripmcnt -The lastcst process - Icleal 1or procluctionsystclrs frorn simple bcnch ntountecl to Lrighspeecl autoltatic CNC - Easy to j igNo ferrnles - No sluoucling gasClc-an welds - No finishing.

The sheet thickncss for SC shoulcl bcgreater than 1 5mm Main applications arervith Milci Steel blLt can also be nsecl u'ithStainless Steel Nlore suitable than CI)rvircre sluface is unevenl coatecl u,'ithoxicic, n'rill scalc or clirt

Nleditrm weight & handportable controllersLower cost t i ran DAblr t more than CD.Three phase 380r '415volt 50IJZ

Lo\1, ( ' () .sl st lrcls , Grextcr str-rcl clesrgrrf l cx i l t i l i t y c l r - rc ro n ( ) p rp rcc l r r i rec lon the r,r,elcl erncl - I lc lr- l iprnc.nt canlrc bench mountecl . \ aLlt() l t t i r t t :cl' l t r lcrates

sr-rrf l rcrc incgrLlal i t ies - Irasy to i ig -

No fcn'r-rle',s

I ) \ g i r c s r h r . g r e r l c s lruraterial penetration.

\\ielcl zone ertencls [o onethircl ol stucL A so Llrrnt l t l o L r g l r l i r r r i t s t h e r n i n i n r r u npletc thickness.

Above 2mm in thickness Milc1 Sreel,Stainless Steel and some AluminiumAlloys. DA is the most tolerant of surfaceirregularities, e.g. rust, mill scale, oil anddirt, Stud weld end is fluxed & lengthincreased by a burn off allowance.

DA controllers ^remobile (on wheels),Can be modifiecl tooperate two hand tools.Three phase 380/175vo \ t .5AHZ

DA is thc most tolerant pfoctess of sr-uf)cei rnper - fe c t ions - Bu lns th roLrgh n ta te r ia llzuninations ' I 'he

only methocl rvhich canrvelcl stucls altorre Nt10 O Corrcct lcngthzrfter welcl (LANfl) ancl nc..lt cven fi1lctinc'licatcs a goctcl w-elcl

Studuelding Improues Design:

Fast

Strong

Accurate

No Reverse Marking

Leak-Proof

Thmper-Proof

Single Side Access

Portable Equipment

Reduced Handling

No'Weakening ofParent Matenal

, - r 1 1 t , , 7 , , .

r ypxcar AppficaH,ovTs:Studwelding provides an "invisible" fixing forfascia panels, countef tops, signs and badges - forany surface where final appearafice, secufity orhygiene is paramount.As studwelding does not break through thesurface, there is no subsequent risk of leaks orcorrosion on, for example, inspection hatchesand cover plates; when mounting heatingelements or attaching fluid chambers.Studwelding is ideal for applications whereaccess cannot be made to the revefse side of anassembly, such as mounting circuit boards,rails, instruments, earth points and manydifferent components.Studwelding is suitable for fixing fluid and airlines, wiring looms, machine guards, handles,insulation and fireproofing materials.

The Weld Studs:From M2.5 to M24 diameters, Studfast supplies adiverse and vast tange of fasteners - available inmild steel, stainless steel, aluminium alloy andbrass.Ve stock externally and internally threadedstuds; plain pins; earth tags; brackets and speedfix washers.Special designs are avallable with short leadtimes.

Stud,utclding e u/s eo.s ts:

W.e have the most comprehensiverange avallable - you can choose fromfifteen controllers, ten handtools andfive production heads.That fneans you get the system bestsuited to your requirements and yourbudget. From ahand portable unit foroccasional use to high speed, fullyautomatic, production systemsStudfast has the solution.

Each handtool is balanced, durableand light to minimise any operatorfatigue, and facilitate fast operation.Adjustments for weld control, studlength and diameter changes take justa few seconds. Front end caps aremanufactured from aluminium tokeep the handtools lightweight andensure accurate fixing points forattaching additional accessories.Our extensive selection of theseaccessories has been developed toassist with accessibility problems,improve jigging and reduce noiselevels.

The controllers provide the powersource. DA controllers can be modi-fied to operate two handtools, eachwelding different stud diameters.

Studfost Studu,relding Ltd.5 Low Farm PlaceMoulton ParkNorthampton NN3 6FfY

CD controllersuse advanced invertertechnology, to makethem lightweight and portable. AIl our controllers are compact,robust and mobile, with stabilized settings which allow for ,Llirraccurate adjustments - achieving the highest quality welds.

All electrical components ate soak tested for

reliability. Unintentional firing is preventedby safety circuits and, in the event of acomponent failure, system shutdown will occur.

High speed systems, custom built to exactspecifications, achieve the best accufacy andproductivity, whether a simple bottom loadedpneumatic production head, or automatic studfeed with CNC positioning and remotedelivety / removal of components.

For additional quality assurance a portable weld monitor can be suppliedto give non-destructive testing.

Studfast's modular approach toequipment enables us to deliver

exactly what you need tohelp your business.

Tef : 01604 79O9Ol

Fox: 01604 492946