ARC STUD WELDING

MANUFACTURED AND SUPPLIED BY

TABLE OF CONTENTS
Page Stud Welding Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 Wear Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Standard Arc Studs & Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8 Koco Stud Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 10 Koco Stud Welding Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 12 Headed Concrete Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Headed Shear Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Headed Concrete Anchors and Shear Connectors Standard Sizes . . . . . . . . . . . . . . . 15 Arc Stud Weld Inspection (Visual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Composite Beam Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Drawn

Arc Stud Welding

Stud welding with ceramic ferrule

Stud welding with shielding gas

Short-cycle stud welding with or without shielding gas

The stud is placed against the workplace.

The stud is lifted off, while current is flowing, thus creating an arc.

The arc melts the surfaces of stud and workpiece.

The stud is plunged into the weld pool.

A cross-sectional joint is achieved.

The

Selection of the Process

Stud welding with ceramic ferrule 1/4 d 25 16 20 bright metal, rolling skin, primer suitable for welding, surface rust, thin layer of oil. Stud welding with shielding gas 1/8 d 12 (16) 6 8 bright metal, rolling skin, primer suitable for welding, surface rust, thin layer of oil zinc coating. loose layers of scaling, heavily corroded, protective coating. Short-cycle stud welding 1/8 d 12 8 10 bright metal, rolling skin, surface rust, thin layer of oil, zinc coating. loose layers of scaling, heavily corroded, coating with organic material. Stud welding with tip ignition 1/10 d, min. 0,5 mm 8 8 8 (for aluminium 6 in all cases) bright metal, thin layer of oil, galvanised (with a possible limit to the stud diameter. zinc coating of more than 15 m, coating with organic material, coating with insulating material (e. g. anodised aluminium. studs from M 6 to M 12 in downhand position, especially with automatic feeding of studs. studs from 5 to 10mm without shielding of the weld pool in case of average quality requirements for the shape of the weld collar. In case of high-grade requirements, shielding gas should be used. for thin metal sheets, especially stainless steel and aluminium, and in case of highgrade requirements for an undamaged visible reverside side.

Process minimum sheet thickness t maximum stud diameter d for welding from different positions suitable surface conditions
1)

unsuitable surface conditions

1)

hot dip-galvanising, loose layers of scaling, heavily corroded, protective coating.

common applications

studs with more than 8 mm in steel and boiler construction, and shipbuilding, on surfaces only coarsely cleaned, deep penetration, suitable for field welding.

1)

Here, we can give only general hints without any commitment or warranty on our part. The conditions must be tested in each individual case. Basically, a higher degree of surface cleanliness is required for shorter welding times. The best results are always achieved on bright metal surfaces.

ArcFix Wear Studs

Applications for this cost cutting technique:

Deep Mining Industry Open Pit Mines Quarries Tunneling Steelworks Ore Preparing Repair-shops for building machines Manufacturers of mining and building machines

Main benefits: High abrasion resistance Quick application on site Permanent protection Studs will not pop off, even when shovels or plates buckle. Cost cutting In comparison with conventional welding, stud welding takes only a quarter of the time for the same surface. Therefore, you save on electric power, and reduce heat with the consequence of less risk of warping.

M16 Diameter M20 Diameter Hardness: 56 - 60 HRc.

ArcFix Wear Studs

PRIMARY DESIGN CONSIDERATIONS

PARENT METAL ANALYSIS ARC stud welding can only be considered if the parent metal is weldable. Proper results can be produced with standard techniques only when low carbon or low alloy steel or austenitic stainless steels are used as parent metals. Other steel alloys can be welded, but may require heat treatment or other special techniques to develop full weld strength. Some brass, copper and aluminium alloys can also be stud welded. However, brass, copper and exotic metals are best welded by the CD method. Because there are so many alloys, it is difficult to cover all variations here. When parent metal analysis is questionable, call your ARCFIX sales engineer for help. Quite often, for instance, weld qualities can only be determined through actual mechanical testing of a prototype sample. We maintain facilities for this purpose and your ARCFIX sales engineer should be called upon to provide sampling and test data service whenever necessary. Fastener Design Ratio Our experience has shown that to assure complete fastener strength development, the parent metal thickness should be at least 1/3 of the weld base diameter of the stud. For application where strength is not the primary requirement, the parent metal thickness may be reduced to a minimum of 1/5 the weld base diameter. By staying above this minimum ratio, complete cross-sectional-area weld fusion without burn-through or excessive distortion of the parent metal, is achievable. Selecting the Proper Stud It is impossible to include specifications of all the various styles and sizes that have been produced and are readily available. Therefore, the purchaser is not limited in choice to those shown in the following pages. In order to achieve lowest fastener cost, first consideration should always be given to: Ordering Studs Follow To Order instructions. 1. Standard stud types 2. Standard lengths and diameters 3. Standard material composition Standard Studs Each of the following specification sheets detail stud styles that have been developed through a long history of usage and manufacturing experience. These specifications were developed to establish economical, useful, standard dimensions. The dimensional limits given do not, however, preclude our ability to manufacture stud welding fasteners with dimensions outside the established figures. Special Studs Most normal machining operations cross drilling, slotting, bending, swaging, piercing, etc are available in combination with many of the studs detailed on the specification sheets. Infinite styles of studs can be produced through these secondary machining operations. Depending upon the application, a special stud may provide even greater in-use economies than a standard stud. Consult your ARCFIX sales engineer: we may already have designed your special. There are many critical dimensions in manufacturing. ARCFIX welding studs give consistent welding results. One important note: After weld (AWL) length is the length the fastener has been engineered for. However, arc welding studs up through 16mm diameter reduce approximately 3mm in length in the welding process; larger diameters will reduce 5mm. The studs, as shipped, will be correspondingly longer than the desired AW length.

Follow To Order instructions given for specific studs ordered: To Order: Specify type of stud; quantity; TxL (AWL) dimensions; type of material and arc shields or any other dimensions necessary.

ARCFIX ALSO SUPPLY ALUMINIUM ARC STUDS TO ORDER. P.O.A.

STANDARD ARC STUDS

FULL THREAD (FT) REDUCED BASE (FRB)

NO THREAD

TAPPED THREAD

Arcfix Standard Arc Stud Load Strengths

LOW CARBON STEEL Thread Size 6mm 8mm 10mm 12mm 16mm 20mm 24mm Material Mechanical Properties Fastening Torque (Nm) 5.8 12.6 20.8 45.8 98.3 123.2 187.6 C 0.23% max Mn 0.60% max Ultimate Tensile (kn) 8.9 14.4 21.4 38.9 63.2 93.0 129.0 Ultimate Shear Load (kn) 6.7 10.8 16.1 29.2 47.4 69.7 97.6 Fastening Torque (Nm) 8.5 14.9 26.7 58.4 125.4 172.9 263.1 STAINLESS STEEL Ultimate Tensile (kn) 12.8 20.8 30.8 56.9 92.5 133.4 185.6 Ultimate Shear Load (kn) 9.6 15.6 23.1 42.7 68.4 100.1 138.8

P 0.04% max S 0.05% max

AISI grade 304 Other grades available on request Values for various grades available on request

Tensile.......................380MPa (min) Elongation.................10%

These values should be used as a guide only, it is impractical to provide precise torque loadings for all conditions.

STANDARD ARC STUDS & PART NUMBERS

Mild Steel Arc Studs
Length 20mm 25mm 30mm 35mm 40mm 45mm 50mm 55mm 60mm 65mm 70mm 75mm 80mm 85mm 90mm 95mm 100mm M6 AS11-06-020 AS11-06-025 AS11-06-030 AS11-06-035 AS11-06-040 AS11-06-045 AS11-06-050 AS11-06-055 AS11-06-060 AS11-06-065 M8 AS11-08-020 AS11-08-025 AS11-08-030 AS11-08-035 AS11-08-040 AS11-08-045 AS11-08-050 AS11-08-055 AS11-08-060 AS11-08-065 M10 AS11-10-020 AS11-10-025 AS11-10-030 AS11-10-035 AS11-10-040 AS11-10-045 AS11-10-050 AS11-10-055 AS11-10-060 AS11-10-065 AS11-10-070 AS11-10-075 AS11-10-080 AS11-10-085 AS11-10-090 AS11-10-095 AS11-10-100

Length 20mm 25mm 30mm 35mm 40mm 45mm 50mm 55mm 60mm 65mm 70mm 75mm 80mm 85mm 90mm 95mm 100mm

M12 AS11-12-020 AS11-12-025 AS11-12-030 AS11-12-035 AS11-12-040 AS11-12-045 AS11-12-050 AS11-12-055 AS11-12-060 AS11-12-065 AS11-12-070 AS11-12-075 AS11-12-080 AS11-12-085 AS11-12-090 AS11-12-095 AS11-12-100

M16 AS11-16-020 AS11-16-025 AS11-16-030 AS11-16-035 AS11-16-040 AS11-16-045 AS11-16-050 AS11-16-055 AS11-16-060 AS11-16-065 AS11-16-070 AS11-16-075 AS11-16-080 AS11-16-085 AS11-16-090 AS11-16-095 AS11-16-100

M20 AS11-20-020 AS11-20-025 AS11-20-030 AS11-20-035 AS11-20-040 AS11-20-045 AS11-20-050 AS11-20-055 AS11-20-060 AS11-20-065 AS11-20-070 AS11-20-075 AS11-20-080 AS11-20-085 AS11-20-090 AS11-20-095 AS11-20-100

Add Suffix to Part Number to Indicate Stud Type. FT = Full Tread Eg. AS11-12-050FT RB = Reduced Base Eg. AS11-12-050RB PT = Part Thread (as per customer request)

STANDARD ARC STUDS & PART NUMBERS

Stainless Steel Arc Studs
Length 20mm 25mm 30mm 35mm 40mm 45mm 50mm 55mm 60mm 65mm 70mm 75mm 80mm 85mm 90mm 95mm 100mm M6 AS12-06-020 AS12-06-025 AS12-06-030 AS12-06-035 AS12-06-040 AS12-06-045 AS12-06-050 AS12-06-055 AS12-06-060 AS12-06-065 M8 AS12-08-020 AS12-08-025 AS12-08-030 AS12-08-035 AS12-08-040 AS12-08-045 AS12-08-050 AS12-08-055 AS12-08-060 AS12-08-065 M10 AS12-10-020 AS12-10-025 AS12-10-030 AS12-10-035 AS12-10-040 AS12-10-045 AS12-10-050 AS12-10-055 AS12-10-060 AS12-10-065 AS12-10-070 AS12-10-075 AS12-10-080 AS12-10-085 AS12-10-090 AS12-10-095 AS12-10-100

Length 20mm 25mm 30mm 35mm 40mm 45mm 50mm 55mm 60mm 65mm 70mm 75mm 80mm 85mm 90mm 95mm 100mm

M12 AS12-12-020 AS12-12-025 AS12-12-030 AS12-12-035 AS12-12-040 AS12-12-045 AS12-12-050 AS12-12-055 AS12-12-060 AS12-12-065 AS12-12-070 AS12-12-075 AS12-12-080 AS12-12-085 AS12-12-090 AS12-12-095 AS12-12-100

M16 AS12-16-020 AS12-16-025 AS12-16-030 AS12-16-035 AS12-16-040 AS12-16-045 AS12-16-050 AS12-16-055 AS12-16-060 AS12-16-065 AS12-16-070 AS12-16-075 AS12-16-080 AS12-16-085 AS12-16-090 AS12-16-095 AS12-16-100

M20 AS12-20-020 AS12-20-025 AS12-20-030 AS12-20-035 AS12-20-040 AS12-20-045 AS12-20-050 AS12-20-055 AS12-20-060 AS12-20-065 AS12-20-070 AS12-20-075 AS12-20-080 AS12-20-085 AS12-20-090 AS12-20-095 AS12-20-100

Add Suffix to Part Number to Indicate Stud Type. FT = Full Tread Eg. AS12-12-050FT RB = Reduced Base Eg. AS12-12-050RB PT = Part Thread (as per customer request)

KCO Compact Stud Welding Equipment

ELOTOP
All models of the ELOTOP compact stud welding equipment series are laid out for top performance as well as highly cost-effective drawn-arc stud welding. Through their special features they are designed for rough wear on building sites and continuous operation. Microprocessor controls, current regulation and high performance ensures precise repeatability and optimum welding results, even under a great variety of conditions. The intelligent self-diagnosis system increases productivity through minimizing machine downtime.

E L OT O P C O M PA C T S T U D W E L D I N G E Q U I P M E N T

KCO Compact Stud Welding Equipment

SERIES ELOTOP
Technical data
Stud welding with ceramic ferrule Weldable stud range (mm) Short cycle stud welding Weldable stud range (mm) Stud welding with shielding gas Weldable stud range (mm) Max: current (A) Current setting range (A) Time setting range (ms) Max. stud/min. at ... (mm) Self-diagnosis: overheating short circuit control mains phase failure malfunction of pilot arc Fully controlled thyristor bridge Microprocessor control Constant current regulation Repeat cycle lock Mains connection 50/60 Hz 3-phase (V) Mains connection special voltages (V) Mains plug at 400 V (A) 4-wire mains cable at 400 V (m/mm2) Mains fusing time-lag at 230/400 V (A) Mains power consumption at ...% ED (kVA) Tolerance range mains voltage (%) Dust and moisture protection of control unit Class of protection Cooling Steel housing, powder-coated Housing dimensions (L x W x H) mm Swivel castors/fixed castors Handle Lifting eye Weight (abt. kg) Shielding gas equipment Stud counter Interface for automatic components Stud welding guns: SK 14 K 22 K 22-D K 24 K 26 = standard, = optional, - = not available 16 5/2.5 35/16 1 29 -15/+6 IP 23 F 375x220x285 1 28 32 5/4 35/25 1.4/3.2/100 55/38/7 -15/+6 IP 23 F 530x305x350 2/2 2 1 50 32 5/4 50/35 2.5/7/100 73/43/12 -15/+6 IP 23 F 600x325x370 2/2 1 1 87 63 5/10 100/63 2.25/9/100 121/59/17 -15/+6 IP 23 F 700x415x460 2/2 1 1 160 63/125 5/16 160/80 2.5/7/100 156/93/25 -15/+6 IP 23 F 805x430x530 2/2 1 1 185 125 5/16 200/125 8/13/100 187/145/52 -15/+6 IP 23 F 960x610x625 2/2 1 1 355 3-8 450 450 20 - 450 15/3 4/8 400 3 - 10 800 50 -750 20 -600 32/3 3/12 230/400 3 - 12 1100 150 - 1000 20 - 1000 49/3 4/14 230/400 3 - 16 1800 150 - 1600 20 - 1500 50/3 2/20 230/400 3 - 16 2300 300 - 2000 20 - 1500 52/3 4/22 230/400 3 - 16 3500 300 -2600 20 -2000 50/6 6/25 230/400 3-6 3-8 3 - 10 3 - 12 3 - 12 6 - 12 3-8 3 - 12 3 - 14 3 - 20 3 - 22 6 - 25

502

802

1002

1702

2002

3002

S Welding under increased electrically hazardous conditions permissible, CE-Labelling according to EN 60974-1 etc.
Upadate 31.3.2006. Subject to technical modifications.

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KCO Stud Welding Guns

CLASSIC
The CLASSIC series of stud welding guns are technologically advanced high performance tools for drawn arc stud welding. They are designed for comfortable operation and known for their sturdiness and reliability. The range includes guns for every application, matching accessories are available. The precision technology of KCO stud welding guns ensures repeatability and produces first-class welding results, even under difficult operating conditions. An adjustable hydraulic plunge damper is standard in the K 22-D, K 24 and K 26 guns, to damp the stud movement when it plunged into the welding pool (recommended for welding studs approx. 14 mm ). All guns are compatible with most commercially available stud welding systems.

CLASSIC STUD WELDING GUNS

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KCO Stud Welding Guns

SERIES CLASSIC
Technical data
Stud welding with ceramic ferrule Weldable stud range (mm) Short cycle stud welding Weldable stud range (mm) Stud welding with shielding gas Weldable stud range (mm) Adjustable hydraulic plunge damper for studs from app. 14 mm Lifting ring system with length compensation Compensation for stud length variations up to ... (mm) Standard support with ... legs Lifting range from ... to ... (mm) Input voltage lifting coil (V=) Welding cable (m/mm )
2

SK 14
4 - 12

K 22
4 - 14

K 22-D
4 - 19

K 24
13 - 22

K 26
13 - 25

3 - 12

6 - 12

3 - 12

3 - 16

2 1 - 4.5 60 - 90 5/35

8 2 1 - 4.5 60 - 90 2/50 50/70 2/4x1.0

8 2 1 - 4.5 60 - 90 2/50 50/70 2/4x1.0

8 2 2.5 - 6 60 - 90 2/95 95 2/4x1.0

8 3 2.5 - 6 60 - 90 2/120 120 2/4x1.0

Welding cable plug (mm )

2

35 5/4x1.0

Control cable (m/mm )

2

Control cable pulg (4 wire) Body: fibre-glass reinforced polyamide (black) Length (excluding chuck) (mm) Body approx. (mm) Height (including handle) (mm) Weight excluding cables app. (kg)

185 50 150 0.9

175 60 165 1.3

175 60 165 1.3

250 60 220 1.4

300 63 240 2.6

= standard,

= optional, - = not available

Upadate 31.3.2006. Subject to technical modifications.

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HEADED CONCRETE ANCHOR

NOTE: L = manufactured length before welding
Shank Diameter Length (L) Head Diameter Minimum head (d) tolerance tolerance height HT 12.7 15.9 +0.00 -0.25 +0.00 -0.25 1.6 1.6 25.40.4 31.70.4 7.1 7.1

General Purpose Studs used for other than shear transfer in composite beam design and construction.

DIMENSIONS IN MILLIMETRES

MATERIAL

LOW CARBON STEEL AS1443 S1010 to S1020 or K1010 to K1020 Tensile...................................380MPa (min) Elongation...............................................10%

MECHANICAL PROPERTIES

FERRULE

*HEADED CONCRETE ANCHORS are available for welding to flat surfaces, inside angles, and outside angles. Each of these applications requires the proper style stud and ferrule, so please specify your application when ordering studs. Ferrule exterior dimensions available on request.

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HEADED SHEAR CONNECTORS

NOTE: L = manufactured length before welding
Shank Diameter Length (L) Head Diameter Minimum head (d) tolerance tolerance height HT 19.0 22.2 +0.00 -0.38 +0.00 -0.38 1.6 1.6 31.70.4 34.90.4 9.5 9.5

Headed Shear Connector are used as an essential component in composite beam design and construction.

DIMENSIONS IN MILLIMETRES
MATERIAL LOW CARBON STEEL AS1445 S1010 to S1020 or K1010 to K1020 Tensile....................................410MPa (min) Yield........................................345MPa (min) Elongation...............................................12% Reduction of area......................50% (min)

MECHANICAL PROPERTIES

SPECS: All ARCFIX STUDS MEET AUSTRALIAN STANDARD, AS1554 Test reports available upon request

FERRULE

*HEADED SHEAR CONNECTORS are available for welding to flat surfaces, inside angles, and outside angles. Each of these applications require the proper style stud and ferrule, so please specify your application when ordering studs. Ferrule exterior dimensions available upon request.

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Headed Concrete Anchors and Shear Connectors Standard Sizes

(Dimensions in millimeters)

CONCRETE ANCHORS
Part Number SC11-13-050 SC11-13-075 SC11-13-100 SC11-16-075 SC11-16-100 SC11-16-150 Size 12.7 x 50 12.7 x 75 12.7 x 100 16 x 75 16 x 100 16 x 150 Weight Ea .079 .104 .129 .161 .199 .278 Pack Qty 250 150 125 125 100 75

SHEAR CONNECTORS
Part Number SC11-19-075 SC11-19-095 SC11-19-100 SC11-19-105 SC11-19-115 SC11-19-120 SC11-19-125 SC11-19-150 SC11-19-175 SC11-19-200 SC11-22-100 SC11-22-125 SC11-22-150 SC11-22-175 SC11-22-200 Size 19 x 75 19 x 95 19 x 100 19 x 105 19 x 115 19 x 120 19 x 125 19 x 150 19 x 175 19 x 200 22 22 22 22 22 x x x x x 100 125 150 175 200 Weight Ea .217 .259 .271 .281 .303 .313 .329 .379 .441 .485 .358 .435 .505 .589 .649 Pack Qty 100 75 75 75 60 60 60 50 45 40 50 50 40 40 35

ALL THE ABOVE STUDS ARE MANUFACTURED AND NATA TESTED TO AS1554. CERTIFICATES AVAILABLE ON REQUEST LENGTHS INDICATED ARE AFTER WELD LENGTHS ACTUAL LENGTH IS 3 5mm LONGER

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ARC STUD WELD INSPECTION (VISUAL)

GOOD WELD
Full, even shiny fillet all around stud.

HOT WELD
Very shiny, low profile fillet extruding beyond outside of ferrule.

COLD WELD
Small, uneven, dull appearing fillet with fingers of metal extending through vents of ferrule.

SHORT PLUNGE OR HANG-UP

No fillet, no stud burn-off, or metal.

MISALIGNMENT
Partial or no fillet, undercut, stud not perpendicular to base, undercut base.

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COMPOSITE-BEAM CONSTRUCTION
Even without the use of metal decking, composite beam construction is, in several ways, superior to slab-on-beam construction. Composite design reduces steel weight. Live load deflection is reduced because of the concretes mass and thickness and the steel beams depth. Overall building height can be reduced because the beams are shallower saving on heating, air-conditioning and exterior and interior wall costs. Longer spans can be used with fewer columns, beams and connections. The results are larger rooms, more useable bay area, and more flexible floor plans. The structure goes up faster; fabrication costs come down. As stated, these benefits are attainable whether you use metal deck or through-deck welding. Consider, however, how much better composite beam construction is when you DO use metal deck and ARCFIX through-deck welding. The job costs less. You dont have to erect wood forms then strip them away, then reerect them. The metal deck which provides a permanent form for the concrete, can also incorporate cellular sections for electrical cables. Ceilings are easier to hang. You build better. Metal deck provides restraint for supporting members, stiffening the structure and giving better load distribution. The deck minimises deflection, reducing the amount of concrete needed. The concrete, itself, is better because the steel retains hydration needed for proper curing. Youll have fewer cracks, easier inspection. You build safer. The metal deck provides a safer, more stable platform for workmen of all trades. Metal deck also eliminates a major construction headache fire in the forms and shoring. Insurance rates are usually lower. These are typical of the benefits you can look for in composite beam/weld-through metal deck construction. Actual savings will, of course, vary with the job.

Cross section of a true composite beam: stud welded shear connectors transfer horizontal shear from slab to beam for maximum strength and load-bearing capacity. With most systems, as shown here, the metal deck provides a positive bond because of the keying of the concrete with the deck ribs. Accordingly, the deck itself can replace all or part of the bottom layer of reinforcing steel, for further economy.

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CONSUMABLES

18

Stud Welding
Shear Connectors Threaded Arc Studs CD Studs CD Pins & Clips CD Welding Machines Arc Stud Welding Machines Stud Welding Machine Spares & Repairs

9 CHICAGO AVENUE BLACKTOWN NSW 2148 AUSTRALIA Tel: 61 2 9622 9622 Fax: 61 2 9622 9199 Email: epitech@epitech.com.au Web: www.epitech.com.au