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STUDWELDING TECHNIQUES
The operating instructions given previously in this guide apply to the majority of general
applications where it is possible to use the pistol in the down hand position and with standard cable
lengths. For many applications these conditions do not apply and the following notes will give some
guidance as to the methods used to obtain satisfactory results for a variety of applications.
1. WELDING TO A PLATE IN THE HORIZONTAL POSITION.
In this position there is a tendency for the weld metal to run to the underside of the stud during
welding, due to the action of gravity, resulting in an uneven fillet. The effect is more noticeable as
stud diameter increases and generally speaking it is not recommended that studs of 12 mm
diameter and over be welded to vertical plates for this reason. The essential requirement to obtain
satisfactory fillet formation is to use the shortest weld time possible with increased welding current.
Welding to a vertical surface reduces the maximum size of the stud a given power source will weld.
It must be remembered, that greater care is required to ensure that the stud is perpendicular to the
work piece. A special tripod foot attachment can be supplied if required. Take particular care to
keep the ferrule grip, foot adapter and chuck clean.
2. WELDING TO A PLATE IN THE OVERHEAD POSITION.
IMPORTANT ! You must protect your face and shoulders with a helmet and cape before carrying out
overhead welding operations. Weld spatter can do a lot of damage !
Firstly, obtain satisfactory weld settings in the down hand position before making attempts in the
overhead position. Since the weld metal is transferred from stud to plate in small particles in the
down hand position, it follows that, when welding overhead, the transfer takes place against
gravity. As with vertical welding the best results will be achieved using the shortest possible weld
time with increased welding current.
It is important that the ferrule grip, foot adapter and chuck are kept free from spatter build up as
this can cause stud return problems or possibly short out/bridge out the weld.
3. PISTOL ADJUSTMENTS WHEN WELDING IN THE VERTICAL OR OVERHEAD POSITIONS.
Problems may be encountered when welding in the vertical or overhead positions with a damped
pistol. To prevent problems occurring, where it is possible to do so, the damping effect should be
removed or turned off.
Welding can then continue as outlined in sections 1. and 2.
4. USING LONG CABLE LENGTHS.
Frequently the pistol must be used some distance from the nearest available mains supply, for
instance on board ship, in power stations and building construction, in workshops building large pre
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fabricated structures etc. In these cases long lengths of welding cable are used and it must be
realised at the outset that, the longer the cables the smaller the maximum diameter of stud which
can be welded with a given power source.
To help get over this problem, if larger diameter studs are to be welded with long lengths of cable,
increase the welding cable conductor size.
Try to avoid running the pistol cables and the earth cables alongside each other as this can cause a
choking effect, reducing power. Also avoid coiling any excess cable as this will have the same effect.
