Archive: May 2015

How to Test Weld Pins, Weld Studs and Cuphead Weld Pins

Weld Pins, Weld Studs and Cuphead Weld Pins

Transcript:

Portable stud-welding is easy to operate and can be used to install many types of fasteners, including things like Weld Pins, Weld Studs and Cuphead (or “mini-Cup”) Insulation Pins.

At Midwest Fasteners, we know that getting work done fast and with reliability is really important to most jobs, and we have ways to help with that. The fast and practical application of Capacitor Discharge StudWelding.

A process often called “CD” welding for short.

Installing Fasteners with “C.D.” welding can be very portable and uses “everyday”, one-hundred-and-ten-volt power.

In addition ease-of-use, CD Welding Systems have:

  • simple parts
  • work quickly
  • and can be used on thin metals to apply a range of Fasteners.

The process of Capacitor Discharge welding occurs in a series of 4 rapid steps:

  • Contact
  • Ignition
  • Placement of the Fastener
  • and “Completion” of the Weld.

Looking at a standard MIDWEST Portable C.D. welder, here are the components of the weld system.

  • a Power Unit, which is plugged into the source for one-hundred-and-ten-volt power
  • a CD Gun with Cables
  • a ground cable and clamping connection
  • and finally, Gun Accessories to fit the fastener to the Gun.

These parts make up the CD system and we are ready to install parts using C.D. Stud-Welding. With the Gun prepared for the fastener to be welded, the Fastener is held in the gun and everything is properly adjusted. The fastener makes contact with the surface to be welded, as the operator locates the weld gun flat to the surface.

Pressure is applied, the CD Gun is triggered, and just that quickly, the CD equipment completes the weld.

The welded part shows NO backside distortion or “BURN-through” and the weld will provide good strength under pressure.

The Strength of the C.D. weld is strong enough to fail in the fastener “before” it fails in the weld, when properly applied. Ultimately, giving us superior strength for holding firmly in place on many types of applications and uses.

Since the CD process can deliver 15-20 welds per minute, material is installed quickly and positively.

One-hundred-and-ten-volt systems can weld as quickly as you load, contact, and weld.

Using the same type set up and steps we can also apply Stud-sized fasteners just as quickly and reliably.

Testing again shows the Strength of the C.D. weld, which is strong enough to fail in the fastener “before” it fails in the weld.

On very light gauge materials, the base of the stud will actually “pull out” of the material, maintaining the weld under stress, rather than show failure in the fastener. In this case the weld is maintained, but base material is not sufficient to support the load, therefore the base metal shows the failure.

But, the C.D. studweld still “Holds”.

Improperly welded parts can be “read” to evaluate problems with application.

As we saw earlier, a PROPERLY welded C.D. part will fail in the fastener, before failing in the weld. That weld also illustrates proper burn-in and weld appearance. Notice the weld has 360-degrees of melted material at the base.

This melting is consistent, tends to ‘adhere’ to the base diameter of the stud, and is not “splashing out” away from the stud base.

A COLD weld looks different and will fail because of too little heat or too little “time” in the weld cycle.

Notice in this sample of a Cold weld, that there is little or NO melted material around the base of the welded stud. Also the stud, or pin, can appear to be “sitting up” on the material and NOT illustrate good bonding “into” the base metal after the weld cycle.

Looking at the failed part, we see a silver, “soldery” appearance and sometimes even “remains of the weld tip” which was not fully ignited.

In this case heat or time needs to be adjusted to work together. We see this most often at Midwest Fasteners, when proper accessories are “not used” or when the accessories are “not used properly” in the set-up o the weld gun .

HOT Capacitor Discharge welds are also easy to spot.

With too much heat or too little weld time, there is a noticeable SPLASH of the weld material away from the stud base. In some cases there is so much splash, that there is just not enough metal to “weld to” as the studweld is made.

A failed HOT part like this also shows a violent, burnout during the weld cycle, giving it the name “HOT weld”.

Again, heat or time needs to be adjusted to work together.

Again we see this from Midwest Fasteners, when proper accessories are “not used” or “not used properly” in weld gun setup AND especially when the C.D. Welder is turned up too high in it’s voltage setting to “solve” weld quality problems—be sure to consult your Owner’s manual, or equipment markings, for proper settings for the diameter and type of part to be welded.

Cuphead or mini-Cup welding is quite different due to the Pin-Welding process for installations of this type.

The welded Cuphead is designed to provide “support” or Pull-Away strength—-strength sufficient to hold material in place.

To test this, pull from under the washer-head of the welded Cuphead. Pulling straight-away from the base tests the weld strength. Properly welded cupheads should withstand this test and feel ‘strong’ in the bond to the base metal.

Cupheads are NOT designed to provide anything more than support strength and will NOT ordinarily show side-to-side, or ‘shear’, strength.

For more on Cuphead welding and how to install and test cupheads, see Midwest Fasteners video “How to Install Cupheads”

AND for more information on Weld Pins, CD Stud Welding, and Midwest Fasteners;

Please visit our leading website at MidwestFasteners.com

How to Install Weld Pins and Weld Studs

Install Weld Pins and Weld Studs

Transcript:

At Midwest Fasteners, we know that getting work done quickly and reliably is really important to most jobs, and we can help with that using Capacitor Discharge Stud Welding.

Easy to operate, portable stud-welding can be used to install many types of fasteners.

These include Weld Pins or Weld Studs, and can be applied using Capacitor Discharge stud welding. A process often called “CD” welding for short.

CD Fasteners can be stud-welded, saving money by doing the fastening work quickly and with reliability.

Installing Fasteners with “C.D.” welding is very portable and uses readily-available electric power from an everyday, one-hundred-and-ten-volt power outlet.

In addition to being portable, CD Welding Systems have:

  • simple components
  • they work quickly
  • and can be used on sheet metal thickness material to apply Welded Fasteners using the capacitor discharge method.

The process of Capacitor Discharge welding occurs in a series of 4 instant steps:

  • Contact.
  • Ignition.
  • Placement of the Stud or Pin
  • and, “Completion” of the Pin Weld

We can use a standard MIDWEST Portable C.D. system to install Weld Pins, here are the component parts of the C.D. System.

  • a Controller [or Power Unit] which is plugged into a one-hundred-ten-volt power outlet to provide weld power and control.
  • a ‘CD’ Gun with Cables, which delivers the welding-grade power and holds the fastener properly during welding.
  • a ground cable and clamping connection which is attached to the work surface to provide the rest of “the circuit” to our weld set up.
  • and finally, special Accessories are needed to fit the Pin to the Weld Gun.

These parts make up the CD system and we are ready to install using Weld Pins using CD Stud Welding.

The Gun is prepared with the chucking accessory know as a “Collet” for this type fastener. Weld pins, properly sized and of the proper type, are held in the gun prior to welding by the Collet. Likewise, the “Foot” on the end of the gun is properly adjusted.

The gun-mounted pin in the Collet makes contact with the metal surface to be insulated, and the operator places the gun flat and flush onto the surface.

With pressure applied to remain rigid and stable, the installer triggers the Pin Gun, and the CD process completes the weld just that quickly.

The equipment now recovers instantly as you break contact with the welded pin, and is ready for the next weld.

The welded pin shows NO backside distortion or “BURN-through” with the weld providing good strength from the bond. The Strength of the C.D. weld is strong enough to fail in the fastener “before” it fails in the weld when applied properly, ultimately giving us superior strength for holding material in place.

Since the CD process can deliver 15-20 welds per minute, material is installed quickly and positively.

One-hundred-and-ten-volt “CD” systems can weld as quickly as you:

  • Load
  • Contact
  • and Shoot

The finished C.D. Weld has the advantages of Capacitor Discharge welding:

  • simple operation with no special power hook ups
  • no special welding enclosures
  • and no weld masks or special welding clothing required

And with that you get fast welded results on lots of fasteners, placed reliably one-after-another, all with good holding power to support material of all types.

Midwest Fasteners’ Capacitor Discharge stud welding is fast, reliable, and gives superior weld strength on weld pins, on weld studs, and on many types of fasteners.

For more information on Weld Pins and CD Stud Welding, please visit our leading website at MidwestFasteners.com

How to Set Up C.D. Weld Studs

Set Up C.D. Weld Studs

Transcript:

At Midwest Fasteners, we know that portable stud welding can be used to install many types of fasteners quickly and with strength for practical use in everyday applications. Setting up for stud-welding is a simple process.

Weld Studs, sometimes called “Stud Welded Fasteners”, can be welded using Capacitor Discharge stud welding or “C.D.” for short. This is a portable welding process which uses readily-available electric power from an everyday, one-hundred-and-ten-volt power outlet.

In addition to being portable, CD Welding Systems have:

  • simple components,
  • work quickly,
  • and can be used on sheet metal thickness material to apply Studs and a variety of Welded Fasteners using the capacitor discharge process

Using Capacitor Discharge for Stud Welding offers a high strength weld, both quickly and reliably.

It can be used with Stainless & Mild Steel — even coated and Galvanized materials— plus Aluminum; with no burn-through of the metal, AND no special weld set-ups required.

The process of Capacitor Discharge welding occurs in a series of 4 fast steps:

  • Contact
  • Ignition
  • Placement of the Stud
  • and “Completion” of the Pin Weld

The standard, portable CD system consists of:

  • The Controller [ or Power Unit] which is plugged into the one-hundred-and-ten-volt power outlet.
  • The CD Gun with Cables which is used to command the power unit and deliver weld current with the Gun also serving as the Stud holder to properly place the fastener during welding.
  • Then, on the other side of “the circuit”, a ground cable and clamp is attached to the work-surface to complete our weld connections.
  • Finally, special Accessories are used to hold the Stud in the Gun.

These parts make up the CD weld system.

It is critical to set the gun up properly, to allow these steps and components to go into action and to allow CD Studs to weld reliably.  There are several ways to set up for stud welding with the MIDWEST CD portable.

First, a simple assembly called,”B” Collet and “B” Stop.

To install these accessories as an assembly, prepare the C.D. Gun, by loosening the screws at the end of the gun-shaft to accept the parts. At the same time, loosen the set screw on each gun leg.

Before installing the Collet, make sure the Collet is the proper size for the stud diameter to be welded. Next, insert a proper length “Stop” into the back of the Collet.

Proper sizing means the Stud will protrude past the end of the Collet, but still be held tight and rigidly during welding.

NEVER allow the head of the stud, or what is call the “Flange” to come in contact with the Collet during welding action.

Insert the Collet and Stop Assembly into the Gun until it “seats” and stops fully.

Next, tighten the set screws, in this case 2 of them, and check to see that the Gun is free and clear to operate smoothly during the weld.

With the Collet installed, insert a Stud fully into the Collet until it stops. Slide the Leg and Foot Assembly until you have only an eighth-of-an-inch of Stud sticking out past the foot. This is called “proper protrusion” and is critical to allow the Welder, Stud and Capacitor Discharge Welding Process to perform properly.

Once the eighth-inch is set, tighten both set screws to keep the foot steady.

If your job requires different length Studs to be used from time-to-time, make this adjustment to each Stud length to be welded, always ending with the critical eighth-inch of protrusion.

That completes set up of The Collet with Stop and you are ready to weld. Just:

  • load
  • contact
  • and weld

And finally where Stud placement requires C.D. welding to place long fasteners, the MIDWEST C.D. gun and it’s special design, can accept another set of accessories to accommodate these jobs with what is called an “Internal Stop”.

Removing the rear cap from the MIDWEST C.D. gun exposes the back side of the gun shaft.

Made with internal threading, this type shaft will accept a “stop-holder” and a “stop”.

Size the stop to accommodate the longer Studs to be used. For extra assistance with stop sizing and length consult the MIDWEST Equipment manuals, accessory parts lists, or your MIDWEST Distributor.

With the stop mounted in the “Holder”, install this assembly into the shaft and replace the Gun’s Main Spring & Rear Cap.

Now install a “B” Collet just like before, with NO stop this time; allowing the stud to pass down-into the gun. The fastener will be held in place at a set stopping-point by the internal-stop and set-up can proceed with adjustment of the foot and legs, which is one-eighth inch protrusion and welding as previously shown.

With any of the MIDWEST Gun accessories shown you can get fast welded results with the C.D. stud welding process.

Midwest Fasteners’ Capacitor Discharge stud welders can cycle for 15-20 welds per minute, and material can be installed quickly and cleanly, using only one-hundred-and-ten-volt power, with reliably welded fasteners, one-after-another, and all with good holding-power to support materials of all types.

For more information on Weld Studs and CD Stud Welding, please visit our industry leading website at MidwestFasteners.com

How to Set Up C.D. Weld Pins

Set Up C.D. Weld Pins

Transcript:

To get work done quickly and reliably is really important on today’s jobs. At Midwest Fasteners, we know that easy to use portable stud welding can be helpful to install all types of fasteners in a fast and practical way. And we know that Midwest Fasteners can help.

Weld Pins, sometimes called “Weld Nails”, can be welded using Capacitor Discharge stud welding, a process that is often called “CD” welding for short.

This is a portable welding process which uses readily-available electric power from an everyday, one-hundred-and-ten-volt power outlet.

In addition to being portable, CD Welding Systems have:

  • simple components
  • work quickly
  • and can be used on sheet metal thickness material to apply a variety of Welded Fasteners using capacitor discharge welding

Using the CD process for Pin welding offers a strong weld quickly and reliably to impale insulating materials. It can be used with Stainless & Mild Steel, even coated and Galvanized materials, plus Aluminum; with no burn-through of the metal, and no special welding setup.

The process of Capacitor Discharge welding occurs in a series of 4 fast steps:

  • Contact
  • Ignition
  • Placement of the Pin and
  • “Completion” of the Weld

The standard, portable CD system consists of:

  • The Controller [ or Power Unit] which is plugged into the one-hundred-and-ten-volt outlet.
  • The CD Gun with Cables is used to command the power unit and deliver weld current, with the Gun also serving as the Pin holder to properly place the pin during welding.
  • Then, on the other side of “the circuit” a ground cable and clamping connection is attached to the work-surface to complete our Capacitor Discharge connections.
  • And finally, special Accessories are used to hold the Pin in the Gun.

These parts make up the CD weld system.

It is critical to set the gun up properly to allow these steps and components to go into action, and to allow pins to weld reliably. There are several ways to set up for Pin-welding with the MIDWEST CD portable pin welder.

First, the simple part called the “Bullet” Collet .

This type Collet requires no additional parts and can be used on Pins up to 4” long.

To install this accessory, prepare the C.D. Gun, by loosening the screws at the end of the gun shaft to accept the Collet. At the same time, loosen the set screw on each gun leg.

Before installing the Collet, make sure the Collet is the proper size for the pin and diameter to be welded.

Insert the Bullet-collet into the Gun until it “seats” and stops fully.

Next, tighten the set screws (in this case 2 of them) and check to see that the Gun is free and clear to operate smoothly during the weld.

With the Collet installed, insert a Weld pin fully into the Collet until it stops. Slide the Leg and Foot Assembly until you have only an eighth-of-an-inch of pin sticking out past the foot. This is called “proper protrusion” and is critical to allow the Welder, Pin and Capacitor Discharge Welding Process to perform properly.

Once the eighth-inch is set, tighten both set screws to keep the foot steady.

If your job requires different length pins to be used, make this adjustment to each pin length to be welded, always ending with the critical eighth-inch of protrusion.

That completes set up of The Bullet Collet and you are ready to weld. Just:

  • Load
  • Contact
  • and Apply

Use of the standard “B” Collet and “B” Stop are similar and can be used for lots of applications as another accessory option. Installation of these accessories occurs as before, as does the final C.D. Gun set up.

Prepare the C.D. Gun the same way, by loosening the screws at the end of the gun shaft, and also on the underside of the gun faceplate.

Remember again, to make sure your accessories are the proper size for the pin and diameter to be welded.

This time, first insert a proper length “Stop” Into the Collet. Then put this assembly into the Gun until it “seats” and stops fully.

Next, tighten the set screws and check to see that the Gun is free and clear to operate.

Now, with the Collet & Stop installed, insert a pin into the Collet, again fully, until it stops. Slide the Legs and Foot until you have the eighth-of-an-inch of pin sticking out assuring proper protrusion and weld timing. Once the eighth-inch is set, tighten both set screws to keep the foot firm during welding.

Again, if your job requires different length pins to be used make this adjustment to each pin length to be welded—always ending with the proper eighth-inch of protrusion.

Welding is simple:

  • load
  • contact
  • and Weld

For an easy setup that requires fewer Collets in the long run, many users prefer a “Collet Protector”. This option gives longer Collet life and allows many length pins to be welded from the same setup; it also prevents “TOO MUCH” pin stick-out, a condition that can cause problems on pin jobs requiring lengths of 6 inches and longer.

Installing accessory parts in this way is also simple. With the gun prepared for accessories, install a Collet (properly sized for pin and diameter) into the gun shaft and tighten it down.

[NOTE: we are using NO stop or other accessory inside the Collet or C.D. Gun]

Next, install a Collet Protector Assembly “over” the Collet. The Collet Protector should also be properly sized to your pin diameter. Tighten it down by the set screws which are part of the Collet Protector Body.

With these parts in place, make the protrusion adjustment until one-eighth inch of pin shows past the “Foot” again, and tighten down the leg screws.

If there is NO change in the pin diameter, then no change needs to be made in your Gun or Accessory setup. With the Collet Protector in use, any length pin is now exposed with proper protrusion at the weld end.

Also Collet life is prolonged versus use of the standard B Collet because it is “protected” from the weld, as well as protected from damage in pull-away or in use.

The design of the MIDWEST C.D. gun allows long pins to protrude through the gun as far as needed, thus preserving the timing-tip exposure which we have set at the weld head of the Pin. Loading and welding goes smoothly, even with different length pins.

And finally, where placement requires Pin-welding to operate in a recess, or where extra “stick out” is needed to get the fastener “TO” the work surface; the MIDWEST C.D. gun and it’s special design, can accept another set of accessories to set-up these jobs with what is called an “Internal Stop”.

Removing the rear-cap from the MIDWEST C.D. Gun exposes the back side of the gun shaft. Made with internal threading, this shaft will accept a “stop-holder” and a “stop”.

Size the stop to accommodate the long pin to be used. (For extra assistance consult the MIDWEST Equipment manuals, accessory parts lists, or your MIDWEST Distributor.)

With the stop mounted in the “Holder”, install this assembly into the shaft and replace the Gun’s Main Spring & Rear Cap.

Now install a “B” Collet just like before, with NO stop; allowing the pin to pass down-into the gun.

The fastener will be stopped at a set point by the internal stop and set-up can proceed with adjustment of the foot-and-legs, one-eighth inch protrusion and welding.

With any MIDWEST Gun accessories shown you can get fast welded results with the C.D. stud welding process.

Midwest Fasteners’ Capacitor Discharge stud welders can cycle for 15-20 welds per minute, and material can be installed quickly and cleanly, using only one-hundred-and-ten-volt power, with reliably welded fasteners, one-after-another,and all with good holding-power to support materials of all types.

For more information on Pin Welding and CD Stud Welding, please visit our website at MidwestFasteners.com