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Stud welding equipment can be a sizable investment for your home or business. Getting the right product at the right price is important for the success of your endeavor. Working with a trustworthy supplier is an excellent way to protect your investment, but knowing what to look for before you buy can help you become an independent, informed buyer. At Stud Welding & Fasteners, Inc., our buyers know they’re getting the best quality products for their needs. Here are a few things to consider before you buy stud welding equipment.

What Type of Equipment Do You Need?

The first step in selecting the ideal stud welding equipment is figuring out the details of your application. There is a variety of equipment available, from arc stud welding equipment to CD (capacitor discharge) units. Have a clear understanding of your application and what tools you need to complete your job before you buy. This includes knowing what maximum stud diameter to shoot, special considerations for the jobsite, the equipment you need, and any special accessories that may make the job easier. Anticipate your needs for the present and future for an equipment investment that will give long-term returns.

What Does the Company Have to Offer?

When researching your options for stud welding equipment manufacturers and sellers, know what you’re getting into. The quality of the equipment is important for your safety and the success of your project. Delve into the company’s history, finding out how many years of experience it has, if there is a proven track record of good service, and whether it offers support during the purchasing process. Special services, high-quality products, and friendly services should be at the top of your list. Stud Welding & Fasteners, Inc. is the only full-service company of its kind in the Southeast. We offer exceptional customer service and expertly crafted stud welding equipment. We go the extra mile every time.

How Much Do You Want to Spend?

Price will always be a main consideration before purchasing stud welding equipment. You don’t want to break the bank, but you should also be wary of prices that are too low. If the price seems too good to be true, they probably are. You might risk purchasing low-quality or knockoff versions of equipment that can prove ineffective and even dangerous to you and your workers. Compare prices from different companies, but be sure to assess the quality you’ll receive for the price. Don’t just hunt for the lowest price or you’ll get what you pay for. Find the company that offers the best value for welding equipment and services.

Are You Prepared for the Future?

As with any investment, you should always think about the longevity of what you’re purchasing. A truly good investment will offer potential returns far into the future. The right company can help you maximize the life span and usability of your equipment with professional installations, repairs, and other services. A high-quality product backed by the support of a trusted stud welding company can help you enjoy returns on investment for the long haul, not just for your upcoming project. For any questions or concerns about stud welding equipment purchases or rentals, contact Stud Welding & Fasteners, Inc.

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Stud Welding & Fasteners Inc. recently acquired the ACE-P100, an insulation pin welder that is a drastic improvement over all the products on the market. We are proud to report that we have already taken delivery of the first unit sold by Tru-Weld.

How Does It Work?

Capacitive discharge stud welding systems weld studs from 14-gauge through 10-gauge weld pins and cup head pins. The welder uses the most up-to-date technology for pin welding. This product has proven to weld pins up to 10 gauge and CD studs up to 10 times faster than other pin welding systems.

This product utilizes new operational and safety features, including less-than-one-second recharge time for pin welding. It offers a touchscreen interface that makes it easier to use. There are thermal and voltage protections that help keep you safe while welding. It also includes contact and trigger indicators to ensure optimal safety while you use the pin welder.

What Are Its Best Features?

Weighing in at just over 10 pounds, the ACE-P100 packs several upgrades and improved features into its compact design. Besides the faster recharge time and intuitive touchscreen, there is a set-point discharge that allows the unit to discharge directly to a new set point. This enables you to continue working without having to discharge completely.

The unit also features universal input voltage, which allows you to plug and play. You will never need to re-tap the machine to adjust it to 110v or 220v input voltages. Its low-input voltage capability allows you to continue with your work without having to use endless extension cords.

Safety indicators are in place to help ensure you and your welder are operating at optimum level. The machine has contact and trigger indicators that can help you troubleshoot your unit. Additionally, the unit uses thermal and voltage protection to prevent it from damage due to overheating.

How Is It Constructed?

The ACE-P100 unit is made of rugged materials; it comes in a lightweight, compact case that helps ease the struggle of carrying around a large welder. The unit is equipped with areas for increased airflow, which helps with efficiency. The rugged materials help ensure no components will become loose after handling and operation.

The new and improved hand tool was redesigned to reduce operator fatigue. This allows you to do more welding. The hand tool is equipped with an internal spring that adjusts to ensure the correct amount of pressure is applied whenever you are welding. The hand tool is also versatile, and can be configured for B collets, collet Inserts, Euro collets, and standard tapered chucks.

Why is this Pin Welder Right for You?

The setup and welding process of this pin welder is simple. The touchscreen allows you to command your welder to do whatever you would like, and it gives you the capability to get your job done quickly and efficiently. Contact Stud Welding & Fasteners Inc. at (800) 936-1948 to find out what the ACE-P100 pin welder can do for your business.

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At Stud Welding & Fasteners, Inc, “Our word is as strong as our weld,” is more than just a motto. It is our company’s mission to be straightforward and honest about our products, working with each customer to provide the best service possible. We pride ourselves on our friendly staff, competent technicians, and services for which our customers can hold us accountable. We are the only full-service stud-welding company in Southeast U.S. to offer service, sales, rentals, and in-shop/field installations. Take a look at our top-selling stud welding products to see what we offer to the welding community.

Tru-Weld Products

When you work with us, you gain access to one of the most reputable stud weld companies in the world. Stud Welding & Fasteners, Inc. gives customers a unique advantage – our partnership with Tru-Weld Stud Welding. Tru-Weld has been a global leader in stud weld products and equipment since 1959 – the era when stud welding first began. Tru-Weld is a pioneer in its industry, creating an original line of high-quality equipment for stud welders.

Tru-Weld has unparalleled products, fast delivery times, and a commitment to customer service. We offer Tru-Weld stud welding products such as studs in any required length, diesel generators, capacitor discharge (CD) stud welders, and anything from their accessories catalog, which includes:

• Adjustable chucks
• CD accessories
• Closed feet
• Ferrule grips
• Ferrule plates
• Headed stud chucks
• Miscellaneous gun parts
• Special chucks/legs
• Special feet
• Split feet
• Weld cable connectors
• Weld thru deck accessories

Stud Welding is proud to partner with Tru-Weld to bring our customers the very best on the market. Tru-Weld only partners with trusted suppliers to provide the utmost quality and customer service every step of the purchase process. Continuous quality improvement is Tru-Weld’s modus operandi – a mode of operation Stud Welding & Fasteners, Inc. is happy to uphold.

Other Stud Welding Products

No matter what stud welding products you need to complete a job or project, we have what you’re seeking. We sell and rent arc stud and CD equipment, insulation pin welders, weld studs, fasteners, and a range of accessories. As the “CD Stud Pros,” we offer the best capacitor discharge stud welding systems, such as the Model TWE-250 CD Stud Welder.

 
This popular product uses the latest solid-state technology to weld studs and pins ranging from 14 through ¼” full-flanged stainless steel studs. Complete with special operational features such as digital voltage read out and powder-coated sheet metal, this Stud Welder is just one of many examples of our impressive wares.

Stud Welding Services

Customers don’t only come to Stud Welding & Fasteners, Inc. for our products – we also offer a list of stud welding services provided by our jobsite division, Elrod Stud Welding. For example, our job site stud welding service comes to your location as a fully insured and approved TDOT subcontractor. View our stud welding job site photo gallery. We rent stud welders and handle small and large embed plate jobs. We use the top techniques and equipment from Tru-Weld to complete all our jobs according to the highest industry standards. Call (800) 936-1948 for a free quote today.

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Tru-Weld Stud Welding is one of the most reputable sources for stud welds in the world. In basic terms, stud welding is the fusion or a metal shaft (or “stud”) to a work piece using a high-power electrical detonation. This yields a stronger bond than traditional forging or welding. Companies have relied on Tru-Weld’s products for decades, but how did this manufacturer become such an industry mainstay? Learn the history of Tru-Weld to see how one company transformed stud welding forever.

1929: Foundation of TFP Corporation

About 30 years before the Tru-Weld name earned a reputation for quality weld studs, it was TFP Corporation, a cold-form manufacturer in Lakewood, Ohio. Cold forming is the process of forging metals at high speed and high pressure, at near room temperatures. TFP Corporation produced cold-form goods and services for 30 years, growing as a company and soon expanding into another, related sector – stud welding.

Mid to Late 1950s: Stud Welding Gains Popularity

In the mid to late 1950s, stud welding had become popular due to emerging technologies and new advancements in engineering and manufacturing. Industries such as construction, automotive, aerospace, marine, and military defense began to demand higher-strength studs and fasteners than manufacturers had previously produced. Stud welding came about as a solution to this problem.

Stud welding fuses a threaded or nonthreaded metal stud or shaft with another metal part, such as a base metal. Stud welding uses a high-speed welding process. First, a hand tool called a stud gun places a welding stud in contact with the base or substrate metal. Then, a weld arc melts the welding stud base and an area for metal fastening. The welding stud is forced into the melted area and held in place until the metal solidifies. This high-quality fusion takes place in just milliseconds using two methods: drawn arc and capacitor discharge (CD) welding.

Drawn arc welding is best for large diameter fasteners and rougher base metals. Stainless steel, aluminum, and mild steel are appropriate base options for this type of welding. CD welding is more appropriate for smaller diameter fasteners and thin base metals. Due to the incredibly fast nature of the weld, it doesn’t distort, burn, or discolor the metals. Manufactures can make almost any shape arc and CD stud, as long as one end of the fastener is designed for arc welding or CD welding.

1959: Tru-Weld Joins the Market

In 1959, TFP Corporation joined the trend toward stud welding. It created the Tru-Weld Division to cater to the growing consumer demand for strong, high-quality, application-specific weld studs. The superb quality and craftsmanship of Tru-Weld’s products quickly led to the division’s success, and it soon became an industry leader of weld stud manufacturing and sales. Tru-Weld produced custom studs for specific industries and customers, all using special manufacturing techniques to ensure their high strength and durability.

1970: Tru-Weld Moves to Medina, Ohio

During the 1960s, Tru-Weld continued to lead the market for stud welds and weld fasteners for everyday tools, yard machinery, automobiles, bridges, aircrafts, ocean liners, steel buildings, military vehicles, and more. Under the capable direction of President Harry Workman, TFP Corporation grew to a total of 25 employees, and slowly began the transition to a new location in Medina, Ohio.

The company chose Medina for its spacious 155,000-square-foot manufacturing plant, which was perfect for TFP Corporation’s rapid expansion. The corporation made the move in multiple stages to minimize the disruption to workflow. Most of the move used rail cars to transport heavy equipment and machinery due to weight restrictions on the roadways. Once the move was completed, TFP Corp. and Tru-Weld really began to thrive, picking up distributors around the nation. The large facility enables the company to keep many common lengths and diameters in stock for faster delivery times.

Tru-Weld Today

Today, Tru-Weld remains one of the most popular weld stud manufacturers in the world. Still operating from its facility on Lake Road in Medina, Ohio, Tru-Weld has stayed true to its original mission and vision – to bring the highest-quality welded products to people around the globe. They are a go-to source for arc stud and CD stud welding, weld studs, and a variety of related equipment. Whether you need welding guns and generators or dependable stud weld accessories, Tru-Weld has what you’re seeking.

Tru-Weld understands the guidelines and best practices for stud welding, such as setting appropriate amperage and time for weld base diameters, aligning accessories correctly, and ensuring a clean and solid ground connection. They’ve been in the business of producing stud well products and accessories since 1959, far longer than most competitors. They continue to invest in emerging technologies to keep their manufacturing practices as safe, efficient, and modernized as possible for the benefit of their customers. To purchase Tru-Weld products from a licensed distributor, come to Stud Welding & Fasteners, Inc.

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Stud welding has been around for a very long time. There are conflicting reports about who actually invented the process. A patent search reveals one possibility. In 1930, Boris S. Robinoff, along with Sumner E. Paine and Wrignol E. Quillen, published patent US1782316A and later sold the rights to Linde Air Products Company. At this point, the company used stud welding for submerged welding in the shipbuilding industry. It wasn’t long before it spread into other construction industries.

What also may have been around a long time is your stud welding equipment. It is common to grow fond of something you have owned a long time, but using old tools may not be a wise idea. Here are some questions to ask yourself that will help with the decision about when to replace welding equipment.

• Is it obsolete? There is a difference between a classic car and a junk heap. Obsolete welding equipment is unlikely to become a classic, so it is a junk heap for sure! It may be hard to part with it, but once you use a newer model with its vast improvements, you won’t miss it.
   
• Is it safe? Old equipment could cost you dearly because of an injury or because the lower-quality welds it produces could hurt your image and lose you some business.
   
• Are you facing repairs? Repairs are costly in several ways. Not only will you be paying for them, but you will lose time on the job, which drops revenue. If your welding equipment is old, you may lose even more time, as it can be difficult to locate parts or find someone that knows how to work on them. When repair costs become greater than replacement costs, it is time to act.
   
• Are you happy with results? If you find yourself constantly dealing with issues or the results are not satisfactory, replace the equipment. Not only is it frustrating to work with obsolete equipment, your welds won’t hold up as they should. Besides, if you are not happy with the results, why would your customer be? In addition, you could be liable should a weld fail.

Troubleshooting Your Stud Welding Equipment

Old equipment can be fraught with problems. Troubleshooting is necessary to decide if you should replace your equipment. Is the issue caused by the equipment, the consumables, the work piece, or user error? The process of troubleshooting will depend on the type and model of the welding equipment you have.

MIG Welding Troubleshooting

Any number of weld defects can result from problems with the equipment or the consumables. To make things more complicated, a defect can result from more than one issue. Here are a few issues:

• Wire is not feeding. This is usually an equipment issue. One or more parts must be replaced, such as the trigger switch, feeder relay, control lead, liner, or adapter connection.
   
• Erratic wire feeding. If the wire is feeding, but erratically, the liner probably needs replacing. There may also be debris buildup.
   
• Short tip life. A number of factors can influence tip life, and it may well be the particular application that is to blame. It can also be user error, such as using the wrong size tip for the task. Other things to check are the drive roll tension setting, low-quality wire, or a defective drive roll.
   
• Erratic arc. Consistent electrical conductivity is required for a proper arc, so look for what is hampering it. Possibilities include erratic wire feeding, worn or improper tip, gun neck is too straight, connections are loose, or liner is worn, damaged, or dirty.
   
• Extreme spatter. Diagnosing this issue is complex and can be either equipment or non-equipment related. User errors include improper weld puddle protection, incorrect tip installation, incorrect shielding gas, and not keeping the nozzles and diffusers clean. Other possibilities include a contaminated work piece and electrical conductivity issues.
   
• Running hot. The most common causes when the gun is getting too hot are loose connections, defective power cable, and exceeding the duty cycle. You can correct the latter only by using a higher-rated gun for the project.

A great source for troubleshooting your welding equipment is the dealer where you purchased it. They can also tell you the benefits of newer equipment and provide tips on maintaining your equipment so it lasts as long as possible. With preventive actions, including cleaning and developing a maintenance schedule, your new welding equipment will give you years of service.

For all your arc welding needs, including sales, service, and rentals, contact Stud Welding & Fasteners, Inc. We’ll help you with new equipment as well as accessories and parts. If you have a short-term need, ask about our rental welding equipment.

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People have crossed waterways and other difficult spans in different ways through the centuries. Durability wasn’t as important back in horse and buggy times, but today’s bridges must be strong. Thankfully, something else changed besides the type of traffic – the 1880s saw the introduction of steel.

Steel did have limitations in the beginning, however. It wasn’t until the 1930s and the development of stud welding that people could use steel to accomplish new feats. Stud welding makes bridges sturdier and permits modern designs. If you want to earn a bridge welder salary you must learn how stud welding works.

What is Stud Welding?

Stud welding, or more accurately, drawn arc stud welding, is a process unlike spot and resistance welding. Rather than using electric current and high pressure, stud welding uses an electric arc. There are two stud welding processes that can be used – capacitor discharge (CD) and arc stud welding.

• Capacitor discharge. This process is semi-automatic and ideal for working with small diameter, shorter studs, and thin materials. Typically, people use this type of welding for sheet metal, not for bridges.
  
   
• Arc stud welding. Ideal for use with a variety of materials of nearly any size, people use arc stud welding for bridges and other structures.
  
   

What are the Benefits?

The beauty of this process is that various materials can be used and the fastener is attached without marring the other side of the workpiece. This makes it aesthetically superior. Stud welding is also more secure and won’t work loose, which is essential for bridges, because of the constant vibration of traffic. Another benefit of stud welding is that it is easy to learn. Even a novice welder should pick up the skill readily.

How to Join a Bridge Crew

Qualification approval for proficiency is necessary before acceptance on a bridge project. This usually involves completing 10 studs in the diameter and position that will be needed. The welder would also be using the same equipment and materials. These are tested for failure by torque testing, bend tests, and other methods.

The visual result is also important. Cold weld, hot weld, or stud hang-up results will disqualify the welder. The visual inspection is looking for even flash, a shiny hue, proper flash height and after-weld length, as well as other guidelines for the project.

How Stud Welding is Used on Bridges

There are many places on bridges that stud welding is used. One important area is connecting the bridge at the ends. You may have noticed that when you drive onto a bridge, you hear a gentle “thump, thump” noise. A metal plate that extends between the bridge and the road causes this. This metal expansion joint allows the bridge to contract and expand with temperature changes. On the back of that plate, stud welding holds it in place by anchoring it to the concrete sets.

Stud welding also creates adhesion between other plates and steel to concrete and reinforced mesh. This is part of the steel girder to slab construction process. Sometimes shear connectors welded to the top flanges of the girders are done off-site and shipped to the project. Other shear connectors must be done onsite.

Outlook for Bridge Construction

In 2016, the American Road & Transportation Builders Association (ARTBA) reported that there are 58,495 structurally deficient bridges in the United States. Other reports put that number much higher and note that more than 20,000 of them are “fracture critical.” More than 12% of bridges in some states are in trouble.

The Federal Highway Administration (FHWA) recognizes that nearly twice the current budget is needed to deal with this backlog, with state, federal, and local governments working diligently to increase their bridge investments.

A number of bridges will be replaced as a result. For example, the new Tappan Zee Bridge will span the Hudson River in New York to replace the Governor Malcom Wilson Tappan Zee Bridge, and should be completed in 2018.

In addition, many interstate bridges are being expanded to accommodate more lanes, improving America’s infrastructure. With all this in mind, the bridge welder market should grow 15% from 2010 to 2020.

Other Applications for Stud Welding

As the industry changes, stud welders will continue to be in demand. Currently, stud welders are needed in more than 200 industries. Growth in many of these, including alternative energy markets, assures job growth for stud welders.

Getting stud welding training and obtaining welding certification, such as through the Ironworkers/AWS National Welding Certification Program, will open doors. Some projects hire certified welders only, so your options will be limited to some degree without certification.

For all your stud welding equipment and service needs, turn to Stud Welding & Fasteners, Inc. where “Our word is as strong as our weld.”

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Friction stud welding might not mean much to people who aren’t in industrial businesses, but the technology is something everyone should be able to appreciate. This modern marvel uses pressure to bond materials in a truly unique way.

The Science of Friction Stud Welding

Friction stud welding is a method unlike any other. Instead of using external heat from electricity, the bond between the materials is formed entirely by friction. The stud is forced against the parent material carefully. More pressure is applied as the stud is rotated at a high speed. The rubbing of the two surfaces causes extreme heat due to friction (hence the name).

The heat is so great that the metals melt and flow. The rotation forces out any surface impurities or other unwanted materials, making the weld clean. The molten metals bond with each other. Rotation is stopped and the weld is completed.

Friction Stud Welding Applications

Friction stud welding is much more costly than arc stud welding. Not only is it more difficult, but it’s also more time consuming. Arc stud welding happens in a matter of milliseconds, but friction stud welding can take several seconds or even minutes to complete.

Although it is trickier, friction stud welding is better suited to certain applications than other types of welding. Arc welding can present problems in certain cases, especially due to the heat and potential for open flames. The presence of electricity can be an issue, as well. As a result, friction stud welding is used in many different cases, including:

• Underwater welding. Electricity cannot be used underwater, yet many items cannot be removed from the ocean for repairs (such as the supports of a permanent oil rig). Friction stud welding is perfect for this application, since it works equally well underwater without additional dangers. Subsea pipelines are another particular example. They can be kept live during the process.
   
• Volatile environments. There are many areas where an open flame or a current of electricity would be dangerous. Any place with explosive gas or certain zoning restrictions is another great candidate for friction stud welding. The bond is made without any open flame or spark, making it much safer in these areas.
   
• Materials which are difficult to join. Some metals are hard to bond in traditional fusion welding methods. Friction welding creates incredible pressure, making it easier to create a full joint between these kinds of metals.
   

Significance of Friction Stud Welding

Each type of welding offers its own advantages and disadvantages. Friction stud welding is useful because it forms bonds at relatively low temperatures, making it safe for sensitive applications and conditions. It also avoids many arc welding problems, like weld contamination. There is no electric current or liquid phase, meaning there is no additional hydrogen, nitrogen, or oxygen. This means cleaner and highly dependable welds.

Friction stud welding also offers a finer weld structure. This is because the cooling time is rapid and the application itself fosters a tighter connection. Friction welding might not be the most cost effective method, but in some cases it is necessary. Friction stud welding without doubt is a fascinating style of welding.

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Like everything else, each type of welding has its own benefits and disadvantages. Different styles are better suited to different applications. Stud welding is more popular than ever thanks to its incredible speed. This quick and efficient type of welding is often used in the manufacturing of cookware, automobiles, aerospace, and marine products, to name a few. Stud welding provides some unique benefits for companies in these industries.

Stud Welding Is Strong

Stud welding is incredibly strong. In fact, the weld itself is much more durable than the stud or the parent material. The joint will often outlast the product, itself. This makes stud welding perfect for mass manufacturing since dependable products can be created quickly.

Stud Welding Is Amazingly Fast

As we stated, stud welding is very, very fast. It only takes milliseconds for the connection to be made. Any time production speed is key, stud welding helps immensely. This is important for smaller businesses, especially, since workers can focus less time on welding and more on assembly, testing, and other portions of manufacturing.

Clean Welds

One of the best things about stud welding is it avoids messy splatter. Other types of welding, like MIG welding, can generate large amounts of excess metal. Aside from being unsightly, weld splatter can actually damage materials and ruin the finish on many products. Even if the item is salvageable it will require reworking, costing more materials and production time. Stud welding offers a clean joint every time. This means there are fewer product losses, even on more delicate items.

Stud Welding Is Versatile

For most welding, the items must be unpainted and sanded. Stud welding is different. Even if the surface is painted or pre-coated, the weld will hold. This saves even more time during preparation, but also makes the welds more versatile since they can be completed at various stages of production.

Cost-Efficiency Of Stud Welding

We’ve all heard the expression “time is money.” It’s never truer than during the manufacturing process. The faster an item can be completed, the lower the cost for the final product. Stud welding is incredibly fast, but as we mentioned, it also takes less preparation and requires minimal cleanup. This means each item will be easier to produce and bring in more profit. No matter what size the company is, more profit is always a good thing.

Stud welding also saves money because the materials are less expensive. Traditional welding rods or wire can cost big bucks, especially when buying them in bulk for production. Opting for stud welding lowers the bill since the material costs are more reasonable, and in some cases, easier to find.

Stud Welding Can Be Easier to Learn

Stud welding doesn’t require quite as much skill as other types. Of course, any time you’re working with molten metal you should have the proper background and take all necessary precautionary measures. However, workers can learn to stud weld more easily, since it requires less prep and cleanup.

Stud welding isn’t the answer for every connection, but it’s an incredible choice for countless applications. It is the product of advancing technology and a constant search for maximum efficiency and value.