Welding Equipment

The Use Of Shear Connectors

Joining two different materials, such as concrete and steel, creates a range of potential issues as the two materials will respond differently to various conditions and factors. For bridge decks, buildings and other structures where concrete and steel are used, the use of the right shear connectors is essential. Due to their critical nature in the structural integrity of any type of building, there are strict standards regarding the size, diameter, and length of shear studs to be used on any project. In addition, there are also specifics on the placement of the shear connectors, which will vary based on the type of project as well as the specific shear force at play based on the design and the application. The Basics With the correct size and placement of shear studs, the two very different materials, the structural steel, and the concrete are permanently fixed to each other. This allows the shear force to be transferred equally between the two, rather than having them move separately. The result is the concrete and the steel act like one. This prevents sagging, buckling, twisting and warping of both materials. Working as one piece, the bridge deck or building becomes stronger and more solid than either material would be on its own. The shear connectors are applied to the steel component through the stud welding process. This is incredibly fast and allows a solid, secure, way to fix the connector to the structural component. This process uses a ceramic ferrule around the base of the stud connector. The operator can install shear studs as fast as he or she can move between locations and position the stud welding gun. This collar or ferrule ensures the proper shielding for the bonding of the shear stud and the workpiece while also allowing the molten material to be held in place for a complete...

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Common Problems When Welding A Shear Connector

With new technology and stud weld systems that require limited configuration and adjustments by operators, stud welding for bridge decks and with composite construction on buildings is a relatively trouble-free job. However, there are some issues that can occur even for experienced operators. These common issues, as well as how to correct issues with welding a shear connector may be as simple as an adjustment of the equipment. Old Equipment While every business wants to use equipment as long as possible, when it comes to drawn arc welding, the equipment can often take a substantial beating. This is more likely to occur if the equipment is used by a lot of different employees, some who may not be as careful with the equipment both when in use and when storing and transporting the welder. Old equipment may simply be failing. This can result in the lift mechanism not working properly, lifting too soon or staying down too long. Issues with the stud plunging too fast can also cause a splash of the molten pool, resulting in a poor-quality weld. Poor Surfaces While generally using drawn arc stud welding and the right type of shear connector will provide a durable, reliable and complete weld, issues with the condition of the surface material can be of concern. This is particularly true if the beam or metal component or plate has extensive rust or flaking on the surface. This damaged surface will result in greater variability in the weld. In turn, this will reduce the weld quality, potentially providing a less durable hold. It is as possible to use the wrong shear connector with the base workpiece. It is possible to find these connectors made of stainless steel or mild steel, with the option to have custom alloys used as well depending on the...

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Training Staff To Use A Stud Welder Gun

Stud welding is not the same as other types of welding including MIG, TIG, and gas welding processes. Generally, most companies assume that their employees have the ability to use a stud welder gun correctly without the need to have a specific employee training on the methods. However, with just as short training or discussion, it is possible to quickly teach everyone on the job how to correctly use this equipment. It can also help to extend the life of the stud welder gun, power supply, and cables. Even with the fixture mounted tools having a general understanding of the equipment will allow employees to have a better understanding of signs of problems or issues with the welds. Keep It Simple The purpose of the stud welder gun is to keep the process of attaching weld studs simple. The new devices are designed to allow for easy and quick setting for different applications and use needs. One of the biggest mistakes that occur is when operators either fail to make the necessary adjustments when changing jobs or when the alter the pre-settings to try to “tweak” the gun. There is no benefit in increasing plunge or decreasing the time of the arc and, in fact, it will weaken the final weld and result in a poorly formed fillet. Heat Issues Heat is needed from the arc to melt both the ignition tip of the stud weld as well as the surface of the base material. The heat is generated by the arc, not through a specific amount of time spent during that phase of the stud welding process. If resulting weld is incomplete or only under the center of the stud welds, operators typically consider this to be a power and time issue. In fact, it is a lift problem, but it can be easily corrected with an...

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The Scope and Range Of Cold Headed Parts

How parts are manufactured and produced has a lot to do with the possible shapes, sizes, and options. There are two basic options in metal fasteners when it comes to production. One is to use heat, and the other is to use cold forming. The Process Cold forming produces what are known as cold headed parts. These are parts made from an existing length of wire, rod or thin bar that will be further processed without adding heat. In large applications, the wire is typically on a coil and is fed by machine into the equipment that will complete the forming process. The metal is not preheated, so there is no change in the internal structure of the alloy. The extreme pressure, which can be as much as 500 tons, will force the cold material through the die very quickly. The other option is to use an extrusion process. This pre-heats the metal to a semi-liquid state and then uses force to push the thick semi-solid metal through a die. It creates a shape, but also produces waste material. For many alloys, there is also additional processing required to reverse the changes in the metal during the process and to relieve the internal strain. The Advantages All cold headed parts are formed using specific pressure applied to the wire. This process almost completely eliminates waste and allows for the complex shaping of the wire or rod in a very cost-effective manner. The systems are fully automated and controlled by computers, allowing for perfect replication of bolts, studs, specialty and custom fasteners without all the cost of hot forming. The cold headed parts produced are near net shape. They may not need any additional processing depending on your needs. The parts produced will be ready for screw machining or grinding processes, saving on time, cost and waste in...

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