Process and Equipment

ARC Studwelding

Drawn-Arc Stud welding (DS)

Short-Cycle Welding time

< 100 ms

Studs Type PS / US / IS (PT / UT / IT)

Thin sheet metals

Automotive industry

Christmas tree studs

Standard Arc Shielding Gas

D ≤ 16 mm

Studs without Aluminum ball

Industrial application

Studs Type RD / PD / ID / UD

Standard Arc Ceramic Ferrule

D ≤ 25 mm

Concrete anchors Shear conectors

Type SD

Jobside applications

Overhead position (PE)

Horizontal Position (PC)

Steel construction

Refractory Anchoring

systems & Pins

Studs Type RD / PD / ID / UD

ARC Studwelding

Drawn arc Processes

ISO 4063

Welding time t

[ms]

Stud diameter

d [mm]

Current intensity

I [A]

Weld pool protection

Minimum sheet

stud welding with ceramic ferrule or shielding gas

783

> 100 3 to 25 300 to 3,000 CF

1/4 d but not less than 1 mm1)

> 100 3 to 16 300 to 3,000 SG

1/8 d but not less than 1mm

Short-Cycle stud welding

784 < 100 3 to 12 up to 1,500 NP,

SG, (CF)

1/8 d but not less than 0.6mm

Capacitor discharge drawn arc stud welding

785 < 10 3 to 10 up to 3,000

(peak) NP

(SG)

1/10 d but not less than 0.5mm

1) The minimum sheet thickness avoids burn through. Other apllication requirements can call for bigger thickness.

Drawn arc processes (ISO 14555)

ARC Studwelding

- Welding gun - Welding head

- Transformer - Inverter

damping of the piston:

stud diameter > 14 mm

ISO 13918

or Shielding gas tube

for Ceramic Ferrule or Shielding gas

ARC - Process Circuit diagram

ARC with Ceramic Ferrule (CF) ARC - Process

Through-deck stud welding • Stud shear connectors are welded on to load-bearing steel structures through thin, mostly hot-dip galvanized cover sheets (thickness: 1.0 to 1.5 mm). • Economically joining principle - uses the same procedure and technology as drawn

arc stud welding • In combination, the stud shear connectors attached by means of drawn arc stud

welding effect the load transmission of predominantly static shear forces between the concrete and the steel beam and the cover sheets serve as permanent formwork for the applied in-situ concrete.

Studs and Ceramic ferrules (ISO 13918)

ARC Welding elements

Type DD Type RD Type PD

Type UD Type ID Type SD Ceramic ferrule

features: ignition cone angle (~23 °) / CF: ignition cone with aluminum ball

Studs and Ceramic ferrules ARC Welding elements

Weld Pool Protection (CF)

Ceramic ferrule (CF) (for studs with Al-Ball) • It forms a combustion chamber around the weld location • Shielding the welder from both arc and spatter • Concentrates the arc in a small region • Reduces heat loss and cooling rate • The atmosphere is only slightly held off • When the stud is plunged into the weld pool, it forces molten metal out

sideways to form an annular weld collar around the stud • Welding in any position can thus be carried out • used only for one weld and is removed once the molten metal has

solidified

ARC Welding elements

Ceramic ferrules for through-deck

ARC Welding elements

Arc ignition at the galvanized sheet metal produces big volumes of vaporized zinc, which is to be removed by degassing holes.

Through-deck ceramic ferrules vs. standard ceramic ferrules • Larger degassing slots to support the degassing • Bigger inside diameter to support the degassing • Larger combustion chamber to be able to accommodate more material (due to longer welding time) • Stronger design of the ceramic ferrule (thermal demands)

Welding parameters ISO 14555 Welding Parameters

Parameters Effect

Welding Current I [A] Size of the melt pool Fluidity of the melt

Welding time t [ms] Penetration Size of the melt pool

Lift L [mm] Geometry of the melt pool Porosity

Protrusion P [mm] Formation of the melt seam Plunging speed Shape of melt seam

Welding parameters ISO 14555 Setup Power unit

Welding Parameters

Welding current [I] A Welding time [t] ms

Dia. < 16mm 80 x D [mm] Dia. < 12mm 20 x D [mm]

Dia. > 16mm 90 x D [mm] Dia. > 12mm 40 x D [mm]

Through-Deck welding 0,8 .. 0,9 (90 x D [mm]) Through-Deck

welding 1.6 .. 1.8 (40 x D[mm])

for normal stud welding of unalloyed steel, Position PA

Lift [L] • Is between (0.8) 1.5 and 8 mm • is proportional to the stud diameter • Coated surfaces: the lift must be greater than it is normally • greater lift increases the arc length and therefore the arc voltage; the

magnetic deflection of the arc also increases (arc blow effect)

Protrusion [P] • Is approximately 1 to 8 mm and proportional to the stud diameter • Depends on: - the desired shape of the weld collar

- the shape of the stud base and - the collar area of the ring (when welding with CF)

Welding Parameters Welding parameters ISO 14555

Setup Power unit

Plunging speed • for studs with a diameter up to 14 mm: approximately 200 mm/s

for studs > 14mm: approximately 100 mm/s so as to prevent the weld pool splashing Polarity • Steel: the stud is connected to the negative pole and the parent

metal is the positive pole • Aluminum: opposite polarity has proven successful for special metals

Arc voltage • values of between 20 V and 40 V • surface impurities such as oil or grease increase the arc voltage

shielding gases reduce the arc voltage

Welding Parameters Welding parameters ISO 14555

Setup Weld Gun

Welding Parameters Welding parameters DVS0903

Welding parameters – Through-deck

Welding Parameters

Reference values of fundamental welding parameters for the through-deck stud welding

SD 19 (1480A / 1.4 s / L 5 mm / P 6 mm) base plate: S355J2G3 (s=12 mm) cover sheet: DX51D + Z275 (s=1 mm) ceramic ferrule for through-deck-stud welding

a) fracture located in the stud when subjected to tensile loading (fracture force: 155 kN), b) radiograph: defect-free welding zone c) transverse section

©SLV München

Grounding

Welding parameters – Arc blow

Welding Parameters

“Golden Rule - Cleanliness”

Clean and dry surfaces allow faster welding, higher process stability and better weld quality.

• Studs and ceramic ferrules must be clean and dry • Cleaning before covering the steel beam with the deck sheet • Deck sheet and steel beam must be clean • Deck sheet must be in uniform contact (tight, distance=0) with the steel

beam • Welding area of the steel beam must be clean

be free from dirt, paint, rust, primer, water, oil, mill scale, concrete,… • Removing layers of weldable paint / primer – especially contents of

Zinc - from the weld zone before welding (increasing the weld quality, lowering formation of pores)

• Only weld at dry surfaces (formation of pores, hydrogen cracks) • Welding below 5°C (surface temperature) needs pre-heating

Welding parameters – Sheet metal

Welding Parameters

Techn. Requirements – Power unit

Welding Parameters

• Electronic regulation of welding current

(constant current / no fluctuations even if the power source is heating up ,compensation of long cables)

• Ignition of the arc through a pilot arc with sufficient electrical contact • Clear parameter settings (as security and comfort for the operator) • “hot plunge” of the stud to avoid lack of fusion • Error code display for fast troubleshooting • Possibility of using welding cable diameter up to 120mm ² for larger

distances (max. 80m) between power source and operator • Safety of the power unit according to actual standards (CE, VDE)

Process Requirements

Welding Parameters

Requirement Transformer Inverter Constant current control

Smooth welding current within the working range

Fast current rise without large overshoots High control frequency

Low weight / high mobility

High efficiency

Energy consumption / Power supply

Output at sensitive / unstable power supply (suitable construction site)

Process monitoring

Wide range of parameter setting (eg. step 1A/1ms)

High welding rate / Sufficient ED (eg. at least 4 studs/min. - Diameter at maximum)

HBS EFFICIENT TECHNOLOGY

Future Technology integrated into our compact and mobile Inverter Series Units

Maximum Welding quality

Best welding quality through extremely high stability of the arc, even at weak welding currents or large fluctuations of the mains voltage.

Maximum Welding rate Highest welding rates - increased by 100% compared to standard conventional transformer technology.

Minimum Energy consumption

Minimized energy consumption - energy needed is reduced by 50% compared to standard power units with transformer technology.

Minimum Weight Minimized weight - Inverter technology reduces the weight by 50% compared to power units with transformer technology.

Maximum Degree of efficiency

Maximum degree of efficiency - innovative inverter technology offers best input / output ratio.

Inverter

Inverter Advantage Inverter vs. Transformer

Transformer Power unit Inverter Control frequency

300 Hz Fluctuation in power output • long cables • high temperature

(a.e. high welding rates • Short welding times (t<100ms)

30.000 Hz (full controled and regulated) High precision regulation for constant power output - Full regulation in the arc ignition time (80ms)

Stromanstiegsgeschwindigkeit ca. 250kA/s Stromanstiegsgeschwindigkeit ca. 850kA/s

Inverter – Series Overview IT 2002 / IT 3002

Power Unit: IT 2002 / IT 3002

Welding Gun: A12 A 16 A 22 / A25 Accessory: Grounding Cable, Chuck

Tripod (Shielding gas or Ceramic ferrule)

Application • Suitable for sheet metal thickness: >2 mm • Suitable for concrete anchors in construction sites • Suitable for through-deck welding • Stud diameter (stud range): M3 up to M24 (Dia. 25 mm / 1“) • Higher requirements with process stability and the quality of the weld • Welding in limited quality and tolerance zones

IT 2002 / IT 3002

Process Max. Welding Current

Stud Diameter Weight

Drawn-arc (ARC) Short-Cycle (SC) 400 V, 3 phase 5 to1,500 ms

2.000 A M3 - M24,

Ø 2 - 22 mm

95 kg 209 lbs

2.600 A M3 - M24,

Ø 2 - 25 mm

160 kg 352 lbs

Inverter – Series

Processes • Short-cycle stud welding (t < 100ms) • ARC- welding (t > 100ms) • ARC - Through-deck welding Equipment • Ceramic ferrule (Standard) • Shielding gas (Option IT 2002)

Power connection: 63 A (400 V)

Suitable stud welding guns • A 12, A 16, A 22, A 25

IT 2002 / IT 3002

Inverter – Series

Power unit Welding power Welding time

Stud diameter Welding rate

(per DVS bulletin 0967)

IT 2002 2.000 A 5 – 1.500 ms

M3 - M24 Ø 2 - 22 mm

Ø 22 – 6 studs/min

IT 3002 2.600 A 5 – 1.500 ms

M3 - M24 Ø 2 - 25 mm

Ø 25 – 6 studs/min

Technical Details Customer Benefit

Welding power IT 2002: 300 – 2000A IT 3002: 300 – 2600A Welding time 5 – 1.500 ms

• Excellent results by working with SC and ARC by

having flexible welding power and welding time • Secure welding of the studs also on critical surfaces like

galvanized and thin sheets • Secure welding of concrete anchors also on critical

surfaces (e.g. through-deck welding) on construction sites

Customer Benefits IT2002/IT3002

Inverter – Series

Equipment Customer Benefit

High Performance and high frequency (30.000Hz) of the inverter allows a dynamic control of the set parameters

• No fluctuation in the power output • No power loss by using longer welding

cables • No power loss at heated power units • Constant power output also by using

shielding gas and ceramic ferrule • Maximum welding quality • Basis for accurate data collection

High arc stability by the inverter technology • Maximum welding quality

Customer Benefit IT - Serie

Inverter – Series

Technical Details Customer Benefits

2 Large wheels 2 Handles Weight: 95 kg

• Most mobile device in its class • Trolley design allows quick transport and high

mobility • Safe for use on construction sites and working

areas • Steps and cables are no longer barriers • No imbalance of the wheels by longer standstill • No punctures and high stability • Handling and weight allow transport in a station

wagon

Lifting eye • Mobile handling and transporting by cranes • Easy transporting

Customer Benefit IT 2002

Inverter – Series

Technical Details Customer Benefit

Through-deck welding • Welding of galvanized sheets by using

concrete anchors • Possible with very stable welding processes

Power connection 63 A (400V) • 125A CEE-connection is not necessary • saving money (can be used everywhere) • High welding rate 6 studs/min.

Robust housing • Especially designed for the use on construction sites

Customer Benefit IT 2002

Inverter – Series

Equipment Customer Benefit

CE-Mark • EU-law: “ free marketable industrial product“

Lifting test • Function control for the gun

IP 23 • Usable on construction sites

Electromagnetical compatibility regarding DIN EN 60974- 10

• Logged quality control • Protection against external influences

High voltage controlled regarding DIN EN 60974- 1

• Logged quality control • Highest protection

Lifting test ARC • To guarantee the functioning of the torch on the welding gun

Error code display • Detection of malfunction

S- Mark • Certificated to weld within increased

electrical risk situations e.g. small rooms and industrial boilers

Customer Benefit IT-Series

Inverter – Series

Arguments

Less weigth / higher mobility / easier transport with 95kg (50%) / 195kg (~70%) less weight

High process stability due to IT Technology, also by using longer cables,

High welding rate (specified in DVS 0967) Dia. 22 - 6 studs/min.

Mains plug: 63A only

Logged high voltage test regarding DIN EN 60974- 1

Protocoled EMC-test regarding DIN EN 60974- 10

High functionality (Before delivering: 500 welding tests and functional test)

Benchmark IT2002 vs. KÖCO

HBS KÖCO KÖCO

IT 2002 ELOTOP 2010 INTOP 2004-1/-2

Schweißbereich

Welding range

M3 – M24

Ø 2 – 22 mm

M3 – RD24

Ø 3 – 22 mm

M3 – M24

Ø 2 – 22 mm

Schweißstrom

Welding Current 300 - 2.000 A 300 - 2.000 A 200 - 2.000 A

Schweißzeit

Welding time 5 – 1.500 ms 20 – 1.500 ms 20 – 1.500 ms

Schweißfolge (Bolzen/ min)

Welding rate (studs / min) 6 (Ø 22) 4 (Ø 22) 4 (Ø 20)

Stromquelle

Power source Inverter

Contr.Trafo / Gleichrichter

Contr.Transformer/Rectifier

Contr.Trafo / Gleichrichter

Contr.Transformer/Rectifier

Maße (L x B x H)

Dimensions (l x h x d) 600 x 500 x 830 mm 805 x 430 x 730 mm 960 x 600 x 830 mm

Gewicht

Weight 95 kg 190 kg 290 kg

Netzstecker (400V)

Mains plug 63 A 125 / 63 A 125 / 63 A

Anschluss

Mains supply 400 V / 3 Phasen 50/60 Hz / 63 AT

400 V / 3 Phasen 50/60 Hz / 80 AT

400 V / 3 Phasen 50/60 Hz / 80 AT

Inverter – Series

Benchmark IT2002 vs. Nelson HBS NELSON NELSON

IT 2002 INTRA 2100 N 4000

Schweißbereich

Welding range

M3 – M24

Ø 2 – 22 mm

M4 – M22

Ø 2 – 22 mm

M6 – M22

Ø 5 – 22 mm

Schweißstrom

Welding Current 300 – 2.000 A 200 -2.100A 300 -2.100A

Schweißzeit / Welding time 5 – 1.500 ms 10 – 1,000 ms 20 – 1,000 ms

Schweißfolge (Bolzen/ min)

Welding rate (studs / min) 6 (Ø 22)

8(M16)

3(Ø 22) 4(Ø 22)

Stromquelle

Power source Inverter

Trafo / Gleichrichter

Transformer/Rectifier

Trafo / Gleichrichter

Transformer/Rectifier

Maße (L x B x H)

Dimensions (l x h x d) 600 x 500 x 830 mm 770 x 520 x 750 mm 850 x 686 x 610 mm

Gewicht

Weight 95 kg 248 kg 330 kg

Netzstecker (400V)

Mains plug 63 A 63 A 63 A

Anschluss

Mains supply

400 V / 3 Phasen

50/60 Hz / 63 AT

400V / 3 Phasen

60Hz/63 AT

400V / 3 Phasen

60Hz/63 AT

Arguments

Less weigth / higher mobility / easier transport with 150kg (60%) / 235kg (~70%) less weight

High process stability due to IT Technology, also by using longer cables

High welding rate (specified in DVS 0967) Dia. 22 - 6 studs/min.

Mains plug: 63A only

Logged high voltage test regarding DIN EN 60974- 1

Protocoled EMC-test regarding DIN EN 60974- 10

High functionality (Before delivering: 500 welding tests and functional test)

Inverter – Series

A 12 A 16 A 22 / A 25 Welding process SC / ARC SC / ARC ARC

Welding range M3 - M12, Ø 3 - 12 mm

Ø 3 - 16 mm A 22: Ø14 - Ø22 mm A 25: Ø14 - Ø25 mm

Application industrial application for welding with shielding gas or with ceramic ferrule

Industry and construction site for welding with shielding gas or with ceramic ferrule

Construction site and through-deck welding „Heavy duty“, for Studs and Concrete anchors till Ø22mm/ Ø25mm

ARC – Weld Guns Weld Guns – technical comparison

Gun Type

Stud Autom. Length

compensation

Adjustments Welding cable

Diameter Length Spring

pressure Max. lift Damping

Length (m)

Diameter (mm²)

Plug (mm²)

Min. (mm)

Max. (mm)

Min. (mm)

Max. (mm)

A 12 2 12 10 150 X (up to 3mm) X 3 mm -- 5,00 35 50

A 16 3 16 10 270 X (up to 6mm) -- 4 mm X 4.85 50 50

A 22 14 22 10 270 X (up to 9mm) -- 6 mm X 4,85 95 95

A 25 14 25 10 270 X (up to 9mm) -- 6 mm X 4,85 120 120

Description: A = ARC – drawn arc Number = maximum stud diameter

Weld Guns – technical comparison

ARC – Weld Guns

Equipment Customer Benefit

Easy handling Easy parameter settings

• Direct visibility of the lift value • Exactly setting by scaling • Flexible setting possibilities • Optimum welding results

Latching setting possibility of the lift and spring value • Unintenional adjustment is not possible

Spirit level • Quick and easy handling for vertical alignment • Ensures stable welding results

Customer Benefit A-Guns

ARC – Weld Guns

Equipment Customer Benefit

Precise length compensation • Constant welding results and high reproducibility

Lightness Compact dimension

• Ergonomic handling • Comfortable and fatigue-free working

Zero-play ball linear bearing for guiding the welding piston

• High plunge speed • Constant moving • Zero-play ball linear bearing • Higher precision then slide bearing

Lightweight bearing • Reproduced setback for constant moving profile and good welding results

Oil plunge damper • For reproduction of good welding results even

with larger stud diameters • No splashing into the melt

Oil lift damper • Constant piston moving profile for stable arc • For reproducing good welds even with big

stud diameters

Customer Benefit A-Guns

ARC – Weld Guns

Equipment Customer Benefit

Robust housing • Shock proof plastic housing for longer life

Kink protection • Protection against kinking of the cable

High flexible cable • Process stability and kink protection

Strain relief • Protection against tear out the cable from the gun housing

General function test Every gun before delivering • High functionality

Using high quality materials: - brand micro switches (Marquardt) - welding connection plugs (DINSE)

• Longer life time • Safeness of the function

Sealed piston • No dust inside the gun • High reliabilty

Customer Benefit A-Guns

ARC – Weld Guns

ARC Studwelding Applications Shear Connector

Applications Shear Connector

ARC Studwelding

ARC Studwelding Applications Shear Connector

ARC Studwelding Applications Shear Connector

Applications / Quality ensurance

No defect (with flat bead)

No defect (preferably

composite, compliant with the requirements

by Eurocode 4)

Pores Shrinkage cracks (insufficient

immersion of the stud)

Welding parameter setting correct

Welding parameter setting correct

Welding current to low

Wrong setting at the weld gun /

weld gun defect

© Bilder: SLV München

Quality

The shear connectors used in composite construction require specific inspections and quality control • Testing procedures are specified in the contract documents or by a local building authority • ISO 14555 / AWS D1.1 specifies the tests and inspections for shear studs

Weld gun Branch Application Recommended

Power Unit Accessories

A 12 Industry IT 1002, IT 2002

IT 50, IT 90, IT 130

Centering device centering tube

Tripod - ceramic Tripod – Shielding gas

A 16 Industry

Heavy Duty

IT 1002, IT 2002, IT 3002

IT 50, IT 90, IT 130

Tripod - ceramic Tripod – Shielding gas

A 22

Industry

Heavy Duty

IT 2002, IT 3002 IT 90, IT 130

A 25

Tripod - ceramic Tripod – Shielding gas

Application and handling

ARC Studwelding

Application and handling

ARC Studwelding