stud welding products StudPro 2500, Operation Manual

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CD 2301 Order No. BA 92-12-0231A Issue 05.01.10 31
5.8.1 Visual Inspection
A visual inspection must be carried out with each welding element.
Condition Possible cause Corrective actions
Good welded joint
Low spatters around the weld
without outer flaws
The weld pool forms a collar around
the flange of about 1 - 1,5 mm
- Correct parameters - None
Cold weld pool
Gap between flange and workpiece
- Heat input too low
- Plunging speed too low
- No sufficient backing of workpiece
- Increase charging voltage
- Adjust plunging speed correctly
- Provide sufficient backing
Hot weld pool
Many spatters around the weld
- Heat input too high
- Plunging speed too low
- Reduce charging voltage
- Increase plunging speed
One-sided weld pool
One-sided spatter collar
Weld pool came out on one side
- Arc blow effect
- Unsymmetric ground connection
- Welding gun put at an angle
- Take care for symmetrical ground
connection
- Put welding gun vertically to the workpiece
Visual Inspection
5 Stud Welding Procedure
5.8 Checking the Quality of the Weld
TESTING YOUR SETTINGS
When you have performed all of the presets as discussed in this manual, it is recom‐
mended that you perform several test welds with the same diameter stud and base
material that you will be using. This will verify that all of the settings are correct to
the results you desire. Welding is done by placing the stud into the collet, and press‐
ing the stud gun to the work piece, compressing the spring. This is why the stud must
protrude beyond the foot piece at least 1/8”.
Holding the gun perpendicular to the work piece, and aligning the stud to the desired
position on the work piece, press down so that the foot piece is flush with the work
piece (spring compressed), and depress the trigger.
When removing the stud gun from the welded stud, always lift the stud gun vertically
from the welded stud in order to maintain the proper tension of the collet. Spreading
the collet when lifting the stud gun from the welded stud will shorten the life of the
collet and will eventually create an undesirable weld.
TESTING WELD SETTINGS