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Section 2

Section 4

Special Welding Techniques

21

21

PROCESS DISCUSSIONS

This section is provided to give a brief overview of different stud welding processes.  If you have additional questions, consult
your distributor for additional information or refer to the “Recommended Practices for Stud Welding”; ANSI/AWS C5.4,
American Welding Society, Inc.

General Process Discussion

The arc stud welding process involves the same basic principles as any other arc welding process.  Application of the process
consists of two steps:

(1) Weld heat is developed with an arc between the stud (electrode) and the plate (work).
(2) The two pieces are brought into contact when the proper temperature is reached.

The time required to complete a weld varies with the cross-sectional area of the stud.  For example, weld time typically would
be about 0.13 seconds for a 10 gage (0.134 in.[2.6 mm]) stud, and 0.92 seconds for a 7/8 in. (22 mm) diameter stud.

There are 4 basic Arc Stud Welding Processes

1. 

Standard Drawn Arc Stud Welding (DASW).  This Process uses a flux load embedded into the weld stud and a

sacrificial ceramic ferrule for shielding.

2.  Gas Arc Stud Welding (GASW).  This process uses no flux load and no ceramic ferrule.  It does rely on shielding gas to

protect the weld zone.

3.  Short Cycle Stud Welding (SCSW).  This process uses no flux, ferrule or shielding gas.  Welds are achieved with high

currents and short weld times.  Welds of this nature are subject to porosity.

4.  Gas Arc Short Cycle Stud Welding (GASCSW).  This weld uses high current and short weld times similar to SCSW, but

adds shielding gas to prevent porosity.

Standard Drawn Arc Stud Welding (DASW) with flux load and ferrule

The stud is loaded into the stud weld tool or weld head chucking mechanism, the ferrule (also known as an arc shield) is placed
into the ferrule grip over the end of the stud, and the weld tool is properly positioned for welding,  The trigger is then depressed,
starting the automatic welding cycle.  Note: The QuikLinx clip is unique in that it does not require a ferrule.

A lift mechanism within the body of the weld tool is energized.  This lifts the stud off the work and, at the same time, creates
an arc.  The end of the stud and part of the work piece are melted by the arc.  When the preset arc period is completed, the
welding current is automatically shut off and the lift mechanism is de-energized by the control unit.  The weld tool plunges
the stud into the molten pool on the work to complete the weld.  The weld tool is then lifted from the stud and the ferrule is
broken off.

The Drawn Arc Stud Welding (DASW) process is the most robust stud welding process.  It can weld effectively and reliably
under a broad range of conditions.  The flux/ferrule combination also provides the greatest weld penetration into the base
material.  Of the available arc processes, this should be the designer’s first choice.  The other processes are typically selected
as a trade off for some factor.

Gas Arc Stud Welding (GASW) (uses shielding gas)

This process is similar to the DASW with a few exceptions.  The stud is loaded into the chuck.  There is a spark
shield used for gas delivery in place of the ferrule grip and the ferrule.  The weld tool is properly positioned.  The trigger is
pulled and gas pre-flow begins.  When the pre-flow time has elapsed the automatic weld cycle begins and follows the same

Содержание QuikLinx SW750

Страница 1: ...afe Practices available from the American Welding Society DO NOT permit untrained persons to install operate or maintain this equipment DO NOT attempt to install or operate this equipment until you ha...

Страница 2: ...cluded with the shipment in a separate box These feet MUST be installed The power source takes in cool air from the the bottom pan If no feet are installed the unit will not properly cool and can over...

Страница 3: ...ssly in lieu of other warranties expressed or implied or for fitness for a particular purpose The liability shall arise only upon return of the defective goods at Buyer s expense after notice to Image...

Страница 4: ...amage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer This symbol appearing throughout this manual means ATTENTION BE ALERT You...

Страница 5: ...tical 8 DO NOT use welding current in damp areas if movement is confined or if there is danger of falling 9 Properly install and ground this equipment according to this Owner s Manual and national sta...

Страница 6: ...yllium or cadmium unless positive mechanical ventilation is provided Do not breathe fumes from these materials 9 If your develop momentary eye nose or throat irritation while operating this is an indi...

Страница 7: ...possible interference keep weld cables as short as possible close together and down low such as on the floor 4 Locate welding operation 100 meters from any sensitive electronic equipment 5 Be sure thi...

Страница 8: ...1 CSA Standard W117 2 Code for Safety in Welding and Cutting American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org 1 ANSI Standard Z8...

Страница 9: ...Safety Precautions Section 1 8 Symbols and Definitions...

Страница 10: ...d at a 5 duty cycle The unit can deliver the full rated current for 1 full second on followed by 19 seconds off While it is possible to deviate from this specific duty cycle i e short rapid bursts or...

Страница 11: ...delivering their rated output when the following environmental conditions prevail Handling Instructions Mass of the SW750 and its various parts require correct methods of handling them e g by fork li...

Страница 12: ...former and control transformer Always verify jumper settings before connecting electrical power to any device Use 7 16 socket wrench or nut driver to ensure the jumper link nuts are tight JUMPER LINK...

Страница 13: ...ER LINK CONFIGURATION B 1 Jumper Link for 460V Links may be stacked for storage 3 Places A B C A C D 1 Jumper Link for 460V 1 Place D Mid Position B 1 Jumper Link for 575V Links may be stacked for sto...

Страница 14: ...lower center back of the back of the welder Connect the ground lead to the identified ground lug first Use the provided lugs to secure this lead Connect the incoming wires to L1 L2 and L3 as shown in...

Страница 15: ...onnector clockwise until it stops Repeat with the weld cable To remove reverse the steps above CONTROL CABLE 4 Line up the key item 3 on the connector on the end of the gun control cable with the key...

Страница 16: ...ion of the welder The power source initiates a self test This test lasts approximately 5 seconds During this test routine none of the welders s functions including welding will operate This is normal...

Страница 17: ...to them As you press and hold the buttons the values change by greater amounts For example you would like to set the welder to 750 amps but the display is showing 50 amps By pressing and holding the c...

Страница 18: ...ettings Your specific circumstance and application may require different settings Always test and validate your weld before using in a production scenario Checking Weld Quality The weld quality can be...

Страница 19: ...GAS MODE The stud welding power supply supports gas arc welding This mode requires a special stud weld gun that is equipped with the proper accessories for gas arc stud welding There are 3 different g...

Страница 20: ...ue of the parameter Example from off to on You may adjust all parameters this way When you have finished adjusting parameters press the gas button This will enter the SAVE mode Use the time buttons to...

Страница 21: ...that the duty cycle has been exceeded Other reasons include inadequate cooling restricted air flow feet taken off etc The thermal LED will be lit at this point When the unit cools down the thermal ov...

Страница 22: ...gas to prevent porosity Standard Drawn Arc Stud Welding DASW with flux load and ferrule The stud is loaded into the stud weld tool or weld head chucking mechanism the ferrule also known as an arc shi...

Страница 23: ...may over ride weld quality and this process may be chosen Gas Arc Short Cycle Stud Welding GASCSW This process combines GASW and SCSW This uses the short cycle process but adds shielding gas to elimi...

Страница 24: ...or general application The other types are subject to air harden ing and they tend to be brittle in the weld area unless annealed after welding The weldable stainless steel grades include American Iro...

Страница 25: ...suitable safe solvent The use of chlorinated hydrocarbons should be avoided A heavy oxide film may require removal by chemical means Welding should take place within eight hours after cleaning Electr...

Страница 26: ...eld rectifier Shorted weld SCR The power source has exceeded the fuse capacity The safety circuit has detected a short Send the unit in for repair Verify proper fusing at the electrical box Trigger li...

Страница 27: ...rformance If the unit is located in a dirty environment the unit should be blown out more frequently Standard Drawn Arc Stud Weld Tool Optional If used Typically most trouble stems from the stud weld...

Страница 28: ...Section 2 Section 7 Exploded Diagram 27 100 102 104 105 106 107 108 109 110 111 112 113 103 114 101 115 116 117 Figure 1...

Страница 29: ...210 200 205 209 201 202 203 204 206 214 208 211 212 213 213 207 Exploded Diagram Section 7 28 Figure 2...

Страница 30: ...300 301 302 303 304 305 306 307 308 Section 2 Section 7 Exploded Diagram 29 Figure 3...

Страница 31: ...Exploded Diagram Section 7 30 406 416 418 401 400 402 404 403 405 415 407 408 409 410 412 411 414 413 417 419 Figure 4...

Страница 32: ...Section 2 Section 7 Exploded Diagram 31 503 500 501 502 Figure 5...

Страница 33: ...Exploded Diagram Section 7 32 600 601 608 607 603 606 605 604 609 610 602 605 605 605 Figure 6...

Страница 34: ...ure 2 200 Button PRM26 Contactor Assembly Exploded Diagram figure 5 201 User Interface Sheet Metal Asm 10596 500 Contactor Mounting Bracket 10509 202 Display Board Spacer SON26 50 28 501 Contactor PAE...

Страница 35: ...WIRE 3 WIRE 4 WIRE 5 WIRE 6 WIRE 7 WIRE 8 WIRE 10 WIRE 11 WIRE 12 2 WIRE 13 WIRE 12 1 WIRE 2 WIRE 3 WIRE T1 WIRE 12 3 WIRE 19 WIRE 15 WIRE 16 WIRE 33 WIRE 34 WIRE 35 WIRE T3 WIRE GND WIRE 26 WIRE 27 W...

Страница 36: ...Please visit us on the web www imageindustries com twitter studwelding...

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