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Midwest Fasteners Gives the 411 on Stud Welding

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1. Midwest Fasteners Gives the 411 on Stud Welding

   June 5, 2020 11:56 am

   With the resurgence of the automotive industry and other sectors of the economy, such as the building construction industry, the need for stud welding continues to be on the rise. With over 20 years of stud welding experience, Midwest Fasteners understands the importance of quality stud welding products, especially for these industries as well as in other sectors of American manufacturing and construction.

   Here at Midwest Fasteners, stud welding is our specialty. Stud welding can be defined as a process in which a metal weld stud fastener can be applied onto metal parts using a controlled welding arc. A stud gun is used to place the weld stud on the metal whereby a weld arc melts the stud’s base and the receiving material. The welding stud is then placed into the material and both metals re-solidify. This process allows for welding to occur without the metal being pierced or punctured, making it the perfect choice when welding materials onto containment vessels like holding tanks that contain liquids or other surfaces where a fastener is needed but surface condition and characteristics cannot be compromised. Stud welding is also extremely fast; the process is completed in seconds.

   There are two popular methods of stud welding: capacitor discharge stud welding and arc stud welding. Capacitor discharge studs are used when dealing with thinner base metals and can also be used on some dissimilar metal combinations. The process leaves no reverse side marking, only needs 110 volt power as input, can weld up to twenty times per minute, and is used with stud welded fasteners that are under 3/8” diameter or less. Arc stud welding is used for heavier metals with the feature of placing fasteners up to 1-1/4” diameter and needs at least 220 volt power sourcing, or direct current. Ceramic arc shields insure that the weld fillet base is maintained properly under Arc Stud Welding applications.

   Click here for more information about the stud welding process, or email our sales team at sales@midwestfasteners.com.

2. The Perfect Light-Weight Welder for Your Heavy-Duty Jobs

   11:52 am

   At Midwest Fasteners, we’ve got a pin welder that’s sure to change your concept of pin welding: SureShotII is tougher, faster and more portable than most other pin welders available, and it’s the most up-to-date capacitor discharge pin welder in the market. It’s easy to see why more demanding users will choose this welder for their toughest jobs.

   SureShotII can be used for all industrial applications, even in the most rugged environments. From ductwork to flat-work, the SureShotII installs cupheads, weld pins, and weld studs of all types – and you can take this welder with you, wherever you go!

   Weighing in at only 18 pounds, and measuring 14” wide x 12” deep x 6” high, the SureShotII offers many features in addition to its unmatched portability:

   • Hybrid power technology
   • Maximum weld capacity for ultra-light stud welders
   • Dual operating power options
   • Push-button voltage controls
   • On-board diagnostics, with a digital LED’s
   • Rugged non-conductive, non-corrosive exterior in a compact co-polymer case (ideal for use in shipyards and marine environments)
   • Low-profile, heavy-duty cable connections
   • Proven Midwest gun technology… and more.

   Don’t let its small size and light weight fool you: The SureShotII is tough and rugged. It has the power to apply virtually any stud fastener used in today’s insulation markets, using only 110-volt (or 220-volt as a user option). That’s power you can rely on to get jobs done quickly, safely and as efficiently as possible.

   At Midwest, SureShotII is the pin welder of choice for many heavy-duty users, for many different reasons. We’d be happy to tell you more about the rugged features of the SureShotII and how it can meet the challenges of your specific job applications. Give us a call at 1-800-852-8352 or send an email to our sales department. We hope to hear from you soon!

3. Welding Tips from Midwest Fasteners

   11:49 am

   What makes a good stud weld? For a quality welded stud, you always need the proper amount of heat and time (or pressure). With too much or too little of either, you’re simply not going to be able to deliver a quality and consistent bond. Whether you’re talking about CD stud welding, arc stud welding, or any type of stud welded fastening, these are two of the most important requirements to consider.

   Now fortunately, “heat” for stud welding is a somewhat easy factor to measure and control. Fluctuations can be accounted for, and various tools can quantify heat and let operators know if conditions are becoming critical. The problem is: measuring pressure can be a bit more complicated. It differs from heat in that applying pressure in the welding process is a mechanical function.

   Why does this make such a difference? Like with any other mechanical function, there are certain variables to consider. Factors like rust, surface contamination, or friction in parts in use could all have an outside effect on the actual pressure delivered to the stud welding cycle. In addition to this, unlike the heat factor, there are no instruments to tell an operator if the right amount of pressure is being applied in the normal course of stud welding operations. Of course a brand new, factory-supplied gun should be operating at optimal performance; but, after that initial break-in period, a preventative maintenance program should be considered mandatory—as it should for any mechanical device involved in repeated use. For instance, since it is a documented that something in the neighborhood of seventy-to-eighty percent of bad stud weld result is caused by poorly maintained guns, it is suggested that weld guns be disassembled and cleaned at least once per month—depending upon the environment and use conditions for each user.

   By following this type and other simple guidelines, you can ensure that the appropriate amount of pressure is being used every time—that timing for your stud welding operation is under proper control—and that a good-repeatable stud welding result is not far behind.

4. How to Maximize Performance From Industrial Specialty Adhesives

   11:48 am

   Insulation Anchor and Hanger Adhesives are water resistant, thermal shock resistant, and have an uncompromised level of strength. However, their effectiveness depends on proper use. By following these guidelines, you will get the most out of this heavy duty, industrial strength product.

   • SURFACE PREPARATION. Surfaces that are to be bonded need to be clean, dry, and free of contaminants. This includes dust, frost, wax, oil, moisture, dirt, grease, and rust. Do not use over painted surfaces, and remember that many protective coatings are not compatible with anchor adhesive. New concrete surfaces need to cure for 28 days minimum for best adhesion, and all concrete surfaces should be water or sand blasted to remove foreign matter and surface curing agents. Remember to check the quality of the surface where adhesion is applied; loose or unstable surfaces will compromise the strength of the adhesive bond.
   • TEMPERATURE PREPARATION. Adhesive should be stored at room temperature (60ºF to 80ºF) for at least 24 hours prior to use. While working, the adhesive and materials to be bonded should be between 30ºF to 120ºF. Do not apply at temperatures below 30ºF. It is recommended to maintain these surface and air temperature guidelines for the first 72 hours after application, or “curing period,” to allow proper setup and cure of material.
   • ANCHOR INSTALLATION METHOD. Prepare and install one insulation anchor at a time. Apply a dab (about the size of a small walnut) of adhesive to the base with a putty knife and press the anchor firmly into place immediately using a slight twisting motion (maximum open time is 10 minutes). After the anchor has been firmly pressed into place, ensure that a film of adhesive covering the anchor base is protruding through the Anchor perforations. If “fingers” of glue do not protrude through the perforations in the anchor base, the anchoring may not hold.

   By applying these simple rules, you will help create the optimal bonding, strength and benefits from this high-hold, heavy-bodied specialty adhesive.

5. The Do’s of the Pin Welding Process

   11:46 am

   When it comes to proper pin welding, there are certain simple but crucial do’s and don’ts, and it’s important to be aware of them. A minor misstep can make a major difference. Here, we lay out the do’s of the pin welding process:

   • Connect welder to proper incoming AC power (110 volt for most systems).
   • Connect weld gun to negative, Ground to positive receptacles (“straight” polarity) and twist, or properly “lock”.
   • Connect Ground tightly, firmly, and cleanly to work surface, assuring “connection” to all weld points.
   • Use the complete system, including ALL cables and ALL accessories for your application.
   • Make sure Gun is set up for your specific application, and do so properly by tightening all hold-downs, set-screws, and accessory components. Understand and use proper accessories and “technique” for pin in use.
   • Use proper pin for weld surface material: aluminum to aluminum ONLY.
   • Observe “1/8’s”: no more than 1/8” of pressure to the pin, any type, during welding AND when welding Cuphead or Mini-Cup. Pins: use a pin at least 1/8” longer than material depth.
   • Paper Washer or insulated, Cuphead MUST be used on foil-faced, FSK material to prevent arcing to facing and produce full and proper welds.
   • Expect unit to “hum” during each charge cycle.
   • Observe ALL fire and electrical codes, plus rules of common sense.

   Follow each of these steps carefully to ensure safe and successful pin welding. Stay tuned for our next blog post on the don’ts of pin welding….

6. The Don’t’s of Pin Welding

   11:44 am

   

   Now that you’re aware of what’s crucial to DO during the pin welding process, let’s take a look at what you should NOT do.

   • Removing the cover. Don’t do this for any reason when the power is connected.
   • Don’t stand in any water when you’re welding. You also shouldn’t sit any units or cables in any form of water or moisture, and don’t weld in wet clothing.
   • Be careful of flammables. Don’t weld near them or any explosive hazards without proper precautions.
   • Don’t weld without proper eye and body protection. Look away from, and not directly at the weld area during a weld.
   • Don’t lubricate a gun, gun shaft, or any part of a unit.
   • Don’t use a collet or chuck that will not grip the fastener snugly or shows lack of grip.
   • During a weld, don’t move the gun! Wait until the cycle is complete.
   • Don’t push the gun down until the spring in the gun “bottoms” out on any type of weld pin.
   • Don’t attempt to solve quality weld problems by turning the unit up to its maximum power.
   • Don’t coil up cables in loops in one area, especially near a point of weld.

   Please keep the tips from our previous blog (The Do’s of Pin Welding), along with the tips listed in the blog above for safe and optimal pin welding processes! If we can help in any way – please let us know.

7. Choosing the Right Stainless Steel

   11:41 am

   When it comes to insulation fasteners and stud welding, the right grade of stainless steel must be used to ensure proper performance. There are several different grades that meet the requirements of the varying applications, and it’s important to know which one is best for you.

   Material being used for insulation fasteners must fall under the guidelines of the American National Standards Institute (ANSI) and the American Welding Society (AWS). The recommended stainless steel grades are 300’s, and typically these are non-magnetic in their normal annealed state. Under ANSI guidelines, these include: types 302, 304, 305, 309, 310, and 316. 304 (now called 18/8) and 305 are the most common, while the L series (i.e. 316L) is preferred when corrosion resistance is important.

   For higher heat exposure applications, 310SS or 330SS are preferred, and for extreme temperatures, the Inconel series 601 is used for insulation fastening and refractory applications. More specifically, when it comes to heat resistance, the grades of choice are as follows: 302/304/305 for 1400°F; 316 for 1700°; 310 for 1850°; 330 for 2,000°; and 601 for 2,200°.

   When looking for the right stainless steel for your particular application, keep in mind that not all grades are readily available at all times. 304, 310, and 316 are typically easy to obtain, while others might require special order.

   Knowing the right grade of stainless steel for your needs will guarantee the material meets your demands.

8. Improving CD StudWelding with the MIDWEST CD Gun

   11:34 am

   

   Use of the MIDWEST Capacitor Discharge (CD) Weld Gun is one of the best ways to ensure proper welding for many studwelding applications. Within this Weld Gun’s operation, spring pressure applied at the time of welding is a key element to ensure that best welding of your CD Weld Studs takes place. Many users find this is because of the “timing” built into the gun’s action, along with the configuration of the weld tip on each-and-every capacitor discharge weld stud.

   All of our standard CD Guns (CDWG-201-35) come with a standard tension Silver Spring, while the MIDWEST Precision CD Gun (CDPG-200-35) comes with a higher tension black spring. All CD Guns come with a removeable rear-cap design that makes the gun shaft spring interchangeable— and therefore fully adaptable to all types of special applications.

   There are certain recommendations and guidelines to follow to ensure best practices. Of course there can be many special circumstances and conditions specific to individual jobs, and these are just guidelines. However, by following the guidelines as a starting point, they can be a good guide to assist in achieving optimal CD stud welding.

   These are the guidelines we recommend following:

   SPRING	MIDWEST Part #	Applications
   Silver	060-3010-01	Weld Pins: Mild Steel/Copper & Galvanized, Stainless;
   		CD Flanged Weld Studs: Mild Steel/Copper Coated;
   		CD Flanged Weld Studs: Stainless Steel
   Black	060-3010-03	Weld Pins: Aluminum;
   		CD Flanged Weld Studs: Aluminum #6 to #10 dia.
   Red	060-3010-05	Weld Pins: Power Base Weld Pins – ALL;
   		CD Flanged Weld Studs: Aluminum ¼” to 5/16” dia.
   Table content goes here	Table content goes here

   Conditions and applications can vary. Feel free to contact us with any questions regarding these guidelines and recommendations, or any studwelding questions you may encount

   We’ll be happy to help!

9. Midwest Fasteners’ Offers Adhesives

   11:26 am

   Installing anchors and hangers for attaching insulation is no simple task. It requires strong, heavy-bodied material that can effectively and reliably bond metal and/or nylon anchors to metal, concrete or masonry surfaces. Adhesives with the Midwest Fasteners brand meet all of these criteria, and additionally can be used in other general construction applications such as installing metal and/or ceramic wall fixtures or installing tile. Our special non-slip formula has proven to be regular and reliable, hence it is one of our popular offerings and we get orders for it day in and day out.

   Recent studies have suggested that the chemicals known as VOCs, or volatile organic compounds, can react with elements in air to produce ozone and promote air pollution. As a result of these findings, the demand for more environmentally-friendly products has grown exponentially. In addition, the growth in products that are LEED (Leadership in Energy and Environmental Design) compliant has led to the development of greener, more sustainable technologies in a wide range of industries, including those construction related markets served by our products.

   We at Midwest Fasteners are introducing and stocking the Midwest Zero VOC General Purpose Hanger Adhesive (ZVOC), available in gallon containers. Thisproduct is in addition to our standard Adhesive, which we’ve offered in one formula or another for our entire history. Our standard Adhesive is for general purpose applications ranging from insulation anchors, to anchor bolts, and glue-on “spindle” insulation hangers.

   The adhesives, whether ZVOC or our standard GPA Adhesive, boast a variety of unique characteristics:

   • Thermal shock resistance
     
   • High bond strength
   • Water resistance
   • Mildew resistance
   • Immediate grab

   You can find more information on our website at this link.

10. How to Set Up Cuphead Weld Pins

    January 24, 2020 3:45 am

    

    Transcript:

    Getting work done quickly and reliably is really important these days. At Midwest Fasteners, we know that easy to use portable stud welding to install many kinds of fasteners is a fast and practical way to get jobs done. And we know that Midwest Fasteners can help.

    Cuphead Weld Pins, sometimes called “Mini” Cups, can be applied using Capacitor Discharge stud welding. This process is often called “CD” welding for short.

    It’s a portable welding process which uses readily-available electric power from an everyday, 110-volt 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 Cuphead Weld Pins and a variety of Welded Fasteners using this welding method.

    Using the CD process for Cuphead welding offers a high strength weld very quickly and reliably, with minimum labor to install insulating materials. It can be used with Stainless & Mild Steel — even coated and Galvanized materials with no burn-through of the metal, and no special weld setups.

    This type of pin welding is often used to insulate duct work and for application of ductlining insulation, especially when Insulation needs to be applied “remotely” or in-the-Field, on a jobsite.

    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

    Here’s how to set up properly for Cuphead welding with the CD portable. The standard, portable CD system consists of:

    • A Controller [or Power Unit] which is plugged into a 110 volt power outlet.
    • The CD Gun and Cables which are used to control the power unit and deliver weld current. The Gun also serves as the Pin holder, plus places the pin properly during welding.
    • and, A ground cable and clamping connection which is attached to the work and provides the rest of “the circuit” to complete our Capacitor Discharge weld system.

    Finally, special Accessories are used to fit the Pin to the Gun. For Cuphead Pin Welding the accessory is a Magnetic Chucking device.

    These parts make up the CD system and we are ready to set up for Cupheads.

    Prepare the CD Cuphead Gun, by loosening the screws at the end of the gun to accept the Magnetic Chuck.

    Insert the Chuck fully into the Gun until it “seats” and stops.

    Lastly, 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. All parts should be cleanly and tightly connected to assure proper welding of any fastener both at the weld end, through the gun and pin, plus at the ground point.

    A finished Cuphead weld shows the advantages of Capacitor Discharge welding with NO backside distortion or burn-through. The weld provides good strength from the bond, and fastening is created in a short cycle which exhibits strength sufficient to support materials without falling down or pulling loose.

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

    C.D. one-hundred-and-ten volt systems can weld as quickly as you:

    • Load
    • Contact
    • and Apply

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

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

    For more information on Cuphead and CD Stud Welding, see our industry leading website at MidwestFasteners.com

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