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Miller Arc Stud Welding Fundamentals, Manual

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Miller Arc Stud Welding Fundamentals Manual Download Page 20

PRINTED IN USA

©

 2005 Miller Electric Mfg. Co. 1/05

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters

−

USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters 

−

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

www.MillerWelds.com

 

Summary of Contents for Arc Stud Welding Fundamentals

Page 1: ...Arc Stud Welding Fundamentals 003 338B July 2005 Visit our website at www MillerWelds com...

Page 2: ...ntrols 6 2 7 Volt Ampere Curve Constant Current CC Power Source 7 2 8 Duty Cycle Power Source For Constant Current CC Welding 7 2 9 Arc Stud Welding Guns 8 2 10 Pistol Grip Stud Gun Components 8 2 11...

Page 3: ...see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that input pow...

Page 4: ...ibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nea...

Page 5: ...puters and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt ly cor...

Page 6: ...ational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Do...

Page 7: ...such as automotive ship building appliance aero dynamics boilers light or heavy construction preassembled fabrication designs and fit up parts design The process may be utilized on a range of materia...

Page 8: ...welding is a very fast weld done at high amperage The weld requires the rise to peak current within millisec onds However because the weld time is very short typical duty cycles are very low Some non...

Page 9: ...TS 2 8 Duty Cycle Power Source For Constant Current CC Welding 150 35 40 50 60 70 80 90 100 200 250 300 400 500 600 700 DUTY CYCLE RATED OUTPUT 30 25 20 WELDING AMPERES Explanation of charts A nominal...

Page 10: ...rmally weigh between 4 5 lb 2 kg to 9 lb 4 kg with the body being constructed of high impact plastic The stud gun consists of a body trigger and lift mechanism Stud gun accessories consist of a chuck...

Page 11: ...d gun Avoid more than a 5 volts drop in the cables Cable connections and splices are another area to consider Make the best possible electrical and mechanical con nections Use commercially available w...

Page 12: ...le length and tight connections 3 Secondary hook up should be DC straight polarity for steel and stainless steel and reverse polarity for aluminum and magnesium 4 A good ground is essential Use a C cl...

Page 13: ...hed directly to the stud gun The ferrule D Concentrates the arc heat to the immediate weld area D Protects the molten weld pool from atmospheric contamination D Confines the molten metal to the weld z...

Page 14: ...e adjusted to approximate settings shown in stud welding table see Section 3 7 3 7 Recommended Settings For Stud Welding Of Steel STANDARD TABLE METRIC TABLE Stud Size Current Time Stud Size Current T...

Page 15: ...Inspect studs visually or by me chanical testing Problem Poor weld Plunge of stud too short or high amperage Remedy Ensure that stud ex tends 3 32 in to 3 16 in beyond the ferrule Make sure gun action...

Page 16: ...tates Each welding unit before use in production shall be used to weld two stud or shear connectors to separate material in the same general position flat vertical overhead sloping and of similar thic...

Page 17: ...D STUDS Normal Diameter Of Studs Inches mm Threads Per Inch And Series Designated Testing Torque Foot Pounds 1 4 in 6 3 mm 1 4 in 6 3 mm 28 UNF 20 UNC 5 0 4 2 5 16 in 8 mm 5 16 in 8 mm 24 UNF 18 UNC 9...

Page 18: ...Notes...

Page 19: ...auge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNESS REFERE...

Page 20: ...Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA Canada FAX 920 735 4134 International FAX 920 735 4125 European Hea...

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