stud welding products StudPro 2500, Operation Manual

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32 CD 2301 Order No. BA 92-12-0231A Issue 05.01.10
5.8.2 Bending Test
You can purchase from SWP a bending device with inserts for various diameters of the
welding elements.
The bending test serves as an easy work sample and as a check for the selected welding
parameters. The welded joint is stressed by bending in a non-defined way.
‹
Bend the welding element with the bending device once by 30°.
Carry out the test in different directions.
The bending test is passed if a crack or a fracture of the welded zone does not occur.
‹
Please note the instructions on fault recognition and corrective actions in chapter
5.
You don’t need to test all studs. It is sufficient to carry out stud
tests at random.
If the strength of the joint is inadequate, then:
‹
check the setting of the stud welding unit
‹
check whether the surface of welding element and base material are clean and
electrically conductive (must be free from scale, oil, paint, oxide layers)
‹
grind off hardened work piece surfaces (e.g. roll hardening).
‹
Check the piston of the welding gun for ease of movement.
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