Weld Stud Procedures - PDF Version

Stud Welding Procedures

PLUNGE or

STICK OUT

TIME/

SECONDS

SIZE

STUD DIAMETER

CURRENT

3/16” through 1/2”

1/8”

5/8” through 7/8”

3/16”

1” and over

3/16” to 1/4”

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1/4

.20 - .25

350 - 450

5/16

.25 - .30

450 - 600

3/8

.33 - .40

525 - 700

7/16

.40 - .45

675 - 750

1/2

.50 - .55

750 - 925

5/8

.65 - .70

1100 - 1400

3/4

.85 - .90

1450 - 1750

7/8

1.00 - 1.20

1700 - 1950

Thru Deck

3/4

1.00 - 1.40

1550 - 1800

STUD WELDING PROCEDURES

Set time for appropriate weld base diameter.

Set amperage for appropriate weld base diameter.

Make sure negative polarity is to stud weld tool.

Align accessories so they are centered and adjust legs.

At least 3/16” to 1/4” of stud needs to protrudes beyond ferrule.

Have a good clean ground.

Work surface relatively clean so impurities do not affect weld.

This would include cleaning off painted surfaces before welding.

Keep studs and ferrules clean and dry.

Test welds at beginning of each shift or change in stud.

Bend two studs 30° after cooled.

Check burn off (1/8”- 3/16”), color (silver blue & shiny), fillet (360°).

Visually inspect all welds.

WELD STUDS

TIME AND CURRENT GUIDE

Set Screw

Ferrule

Grip

Stud

Foot

Ferrule

(Center Stud

in Ferrule)

Ferrule Grip

Foot

Chuck Adaptor

Leg Screw

Leg

Adjusting Stud Weld Tool Plunge

1.)

Place a chuck into the chuck adapter. Tap on the end lightly to make sure that the chuck is properly seated

in the adapter. NOTE: A different chuck is required for each different stud diameter.

2.)

Insert a ferrule grip into the foot and tighten the set screws on the foot.

NOTE: A different ferrule grip is required for different size ferrules.

3.)

Insert a stud into the chuck and a ferrule into the ferrule grip.

4.)

Loosen the screws holding the FOOT and adjust the foot so the stud is centered in the ferrule.

THIS IS IMPORTANT so there is no binding between the ferrule and the stud. This binding could cause

improper welds (hang-up). A good rule of thumb is that you should be able to work the weld tool

mechanism with the ferrule in place without knocking the ferrule out of the ferrule grip.

5.)

Loosen the leg set screws (one on each side of the weld tool).

6.)

Adjust the legs so that the stud extends 1/8” to 3/16” beyond the end of the ferrule.

7.)

After you have properly positioned the legs, tighten the leg set screws on both sides of the weld tool body.

NOTE: You must readjust the plunge setting whenever changing stud lengths.

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STUD WELDING PROCEDURES

Adjust legs so that 1/8" - 3/16" of

the Stud extends beyond Ferrule

Chuck

Chuck

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