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A luminum Stud Welding Technologies

A luminum Stud Welding Technologies. By Chris Hsu and Clark Champney Nelson Stud Welding, Inc. . Challenges. Low melting point High thermal conductivity Tough oxide (3488F) Spatter Softening. Drawn Arc Stud Welding 101. A. Pilot Arc. B. Lift Main Arc. C. Plunge. D. Remove

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A luminum Stud Welding Technologies

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  1. Aluminum Stud Welding Technologies By Chris Hsu and Clark Champney Nelson Stud Welding, Inc. 2011 AWS Conference and Exhibition Welding in Shipbuilding

  2. Challenges • Low melting point • High thermal conductivity • Tough oxide (3488F) • Spatter • Softening

  3. Drawn Arc Stud Welding 101 A. Pilot Arc B. Lift Main Arc C. Plunge D. Remove Chuck

  4. Capacitor discharge AWS Seattle May 10, 2011

  5. CD welding Process • Weld time • Timing tip • Plunge speed • Current • Cap voltage • Cable impedance • Contact • Gap • Stored Arc 2011 AWS Conference and Exhibition Welding in Shipbuilding

  6. MIL specifications • MIL-S-24149/2D: aluminum stud and ferrule for drawn arc • MIL-S-24149/5C: aluminum stud for CD and stored arc AWS Seattle May 10, 2011

  7. Gun accessories • Gas foot • Tranquil arc plunge dampener • Motorize gun AWS Seattle May 10, 2011

  8. plate thickness to stud diameter ratio • Develop full strength • Steel: 1/3 • Aluminum (Al is annealed in stud welding) • ½ for drawn arc • ¼ for CD AWS Seattle May 10, 2011

  9. Weld strength: tensile/torque AWS Seattle May 10, 2011

  10. Internally threaded studs • Diameter ¼” to ½” • Threads #10-24 thru ½-13 • 5000 series alloy used for stud (Magnesium based) • LNG tankers AWS Seattle May 10, 2011

  11. Pulse cleaning and welding • Cut oxide, rust, oil, mill-scale • Reduce heat input • backside marking • Stiffen arc • Out of position • Angle iron • Aluminum • Peak: cathodic clean • Background: heat Stud Welding Technologies – ShipTech 2011

  12. Process monitor & loggerWelder, Gun and Cable • Weld energy • Stud hang-up • Cold plunge • Cable overheat • Weld Pass / Fail • Production log Normal Cold Stud Welding Technologies – ShipTech 2011 Hang-up Hot

  13. Summary • CD - contact, gap and stored arc • Drawn arc • Pulse • AC • Up to ½” can be welded down hand and plate vertical • Inverter to weld 5/8” and ¾” in flat position • Process monitor • Drawn arc • CD 2011 AWS Conference and Exhibition Welding in Shipbuilding

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