Arcfix Arc Stud PDF
Arcfix Arc Stud PDF
Arcfix Arc Stud PDF
Page
Wear Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4
Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Drawn Arc
Stud Welding
A cross-sectional joint is
achieved.
1
The Selection
of the Process
Process Stud welding with Stud welding with Short-cycle Stud welding with
ceramic ferrule shielding gas stud welding tip ignition
minimum sheet
thickness t 1/4 d 1/8 d 1/8 d 1/10 d, min. 0,5 mm
maximum stud 25 12 (16) 12 8
diameter d for 16 6 8 8
welding from 20 8 10 8
different positions (for aluminium 6 in all cases)
suitable surface bright metal, rolling bright metal, rolling bright metal, rolling bright metal, thin
conditions 1)
skin, primer suitable skin, primer suitable skin, surface rust, layer of oil, galvanised
for welding, surface for welding, surface thin layer of oil, (with a possible limit
rust, thin layer of oil. rust, thin layer of oil zinc coating. to the stud diameter.
zinc coating.
unsuitable surface hot dip-galvanising, loose layers of scaling, loose layers of scaling, zinc coating of more
conditions 1)
loose layers of heavily corroded, heavily corroded, than 15 µm, coating with
scaling, heavily protective coating. coating with organic organic material,
corroded, protective material. coating with insulating
coating. material (e. g.
anodised aluminium.
common studs with more than studs from M 6 to M 12 studs from 5 to 10mm ø for thin metal sheets,
applications 8 mm ø in steel and in downhand position, without shielding of especially stainless
boiler construction, especially with the weld pool in steel and aluminium,
and shipbuilding, on automatic feeding case of average and in case of high-
surfaces only coarsely of studs. quality requirements grade requirements for
cleaned, deep for the shape of the an undamaged visible
penetration, suitable for weld collar. In case reverside side.
field welding. of high-grade
requirements, shielding
gas should be used.
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.
2
ArcFix
Wear Studs
Applications for this cost cutting
technique:
• Deep Mining Industry
• 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.
3
ArcFix – Wear Studs
4
PRIMARY DESIGN CONSIDERATIONS
PARENT METAL ANALYSIS not limited in choice to those shown in the following
ARC stud welding can only be considered if the pages. In order to achieve lowest fastener cost, first
parent metal is weldable. Proper results can be consideration should always be given to:
produced with standard techniques only when low Ordering Studs
carbon or low alloy steel or austenitic stainless Follow “To Order” instructions.
steels are used as parent metals. Other steel alloys
can be welded, but may require heat treatment 1. Standard stud types
or other special techniques to develop full weld 2. Standard lengths and diameters
strength. 3. Standard material composition
Some brass, copper and aluminium alloys can also Standard Studs
be stud welded. However, brass, copper and exotic Each of the following specification sheets detail
metals are best welded by the CD method. stud styles that have been developed through a long
Because there are so many alloys, it is difficult history of usage and manufacturing experience.
to cover all variations here. When parent metal These specifications were developed to establish
analysis is questionable, call your ARCFIX sales economical, useful, standard dimensions. The
engineer for help. dimensional limits given do not, however, preclude
Quite often, for instance, weld qualities can only our ability to manufacture stud welding fasteners
be determined through actual mechanical testing of with dimensions outside the established figures.
a prototype sample. We maintain facilities for this Special Studs
purpose and your ARCFIX sales engineer should Most normal machining operations – cross
be called upon to provide sampling and test data drilling, slotting, bending, swaging, piercing, etc
service whenever necessary. – are available in combination with many of the
Fastener Design Ratio studs detailed on the specification sheets. Infinite
styles of studs can be produced through these
Our experience has shown that to assure complete
secondary machining operations. Depending upon
fastener strength development, the parent metal
the application, a special stud may provide even
thickness should be at least 1/3 of the weld base
greater in-use economies than a standard stud.
diameter of the stud.
Consult your ARCFIX sales engineer: we may
For application where strength is not the primary already have designed your “special”.
requirement, the parent metal thickness may
There are many critical dimensions in manufacturing.
be reduced to a minimum of 1/5 the weld base
ARCFIX welding studs give consistent welding
diameter. By staying above this minimum ratio,
results.
complete cross-sectional-area weld fusion without
burn-through or excessive distortion of the parent One important note: After weld (AWL) length is
metal, is achievable. the length the fastener has been engineered for.
However, arc welding studs up through 16mm
Selecting the Proper Stud
diameter reduce approximately 3mm in length in the
It is impossible to include specifications of all the welding process; larger diameters will reduce 5mm.
various styles and sizes that have been produced The studs, as shipped, will be correspondingly
and are readily available. Therefore, the purchaser is longer than the desired AW length.
5
STANDARD ARC STUDS
6
STANDARD – ARC STUDS & PART NUMBERS
Mild Steel Arc Studs
Length M6 M8 M10
20mm AS11-06-020 AS11-08-020 AS11-10-020
25mm AS11-06-025 AS11-08-025 AS11-10-025
30mm AS11-06-030 AS11-08-030 AS11-10-030
35mm AS11-06-035 AS11-08-035 AS11-10-035
40mm AS11-06-040 AS11-08-040 AS11-10-040
45mm AS11-06-045 AS11-08-045 AS11-10-045
50mm AS11-06-050 AS11-08-050 AS11-10-050
55mm AS11-06-055 AS11-08-055 AS11-10-055
60mm AS11-06-060 AS11-08-060 AS11-10-060
65mm AS11-06-065 AS11-08-065 AS11-10-065
70mm AS11-10-070
75mm AS11-10-075
80mm AS11-10-080
85mm AS11-10-085
90mm AS11-10-090
95mm AS11-10-095
100mm AS11-10-100
7
STANDARD – ARC STUDS & PART NUMBERS
Stainless Steel Arc Studs
Length M6 M8 M10
20mm AS12-06-020 AS12-08-020 AS12-10-020
25mm AS12-06-025 AS12-08-025 AS12-10-025
30mm AS12-06-030 AS12-08-030 AS12-10-030
35mm AS12-06-035 AS12-08-035 AS12-10-035
40mm AS12-06-040 AS12-08-040 AS12-10-040
45mm AS12-06-045 AS12-08-045 AS12-10-045
50mm AS12-06-050 AS12-08-050 AS12-10-050
55mm AS12-06-055 AS12-08-055 AS12-10-055
60mm AS12-06-060 AS12-08-060 AS12-10-060
65mm AS12-06-065 AS12-08-065 AS12-10-065
70mm AS12-10-070
75mm AS12-10-075
80mm AS12-10-080
85mm AS12-10-085
90mm AS12-10-090
95mm AS12-10-095
100mm AS12-10-100
8
KÖCO – Compact Stud Welding Equipment
ELOTOP
All models of the ELOTOP Microprocessor controls, The intelligent self-diagnosis
compact stud welding current regulation and high system increases productivity
equipment series are laid performance ensures precise through minimizing machine
out for top performance as repeatability and optimum downtime.
well as highly cost-effective welding results, even under a
drawn-arc stud welding. great variety of conditions.
Through their special features
they are designed for rough
wear on building sites and
continuous operation.
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
9
KÖCO – Compact Stud Welding Equipment
SERIES ELOTOP
Technical data 502 802 1002 1702 2002 3002
Stud welding with ceramic ferrule
Weldable stud range Ø (mm) 3-8 3 - 12 3 - 14 3 - 20 3 - 22 6 - 25
Short cycle stud welding
Weldable stud range Ø (mm) 3-6 3-8 3 - 10 3 - 12 3 - 12 6 - 12
Stud welding with shielding gas
Weldable stud range Ø (mm) 3-8 3 - 10 3 - 12 3 - 16 3 - 16 3 - 16
Max: current (A) 450 800 1100 1800 2300 3500
Current setting range (A) 450 50 -750 150 - 1000 150 - 1600 300 - 2000 300 -2600
Time setting range (ms) 20 - 450 20 -600 20 - 1000 20 - 1500 20 - 1500 20 -2000
Max. stud/min. at ... Ø (mm) 15/3 32/3 49/3 50/3 52/3 50/6
4/8 3/12 4/14 2/20 4/22 6/25
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) 400 230/400 230/400 230/400 230/400 230/400
Mains connection special voltages (V)
Mains plug at 400 V (A) 16 32 32 63 63/125 125
4-wire mains cable at 400 V (m/mm2) 5/2.5 5/4 5/4 5/10 5/16 5/16
Mains fusing time-lag at 230/400 V (A) 35/16 35/25 50/35 100/63 160/80 200/125
Mains power consumption at ...% ED (kVA) 1 1.4/3.2/100 2.5/7/100 2.25/9/100 2.5/7/100 8/13/100
29 55/38/7 73/43/12 121/59/17 156/93/25 187/145/52
Tolerance range mains voltage (%) -15/+6 -15/+6 -15/+6 -15/+6 -15/+6 -15/+6
Dust and moisture protection of control unit • • • • • •
Class of protection IP 23 IP 23 IP 23 IP 23 IP 23 IP 23
Cooling F F F F F F
Steel housing, powder-coated • • • • • •
Housing dimensions (L x W x H) mm 375x220x285 530x305x350 600x325x370 700x415x460 805x430x530 960x610x625
Swivel castors/fixed castors - 2/2 2/2 2/2 2/2 2/2
Handle 1 2 1 1 1 1
Lifting eye - 1 1 1 1 1
Weight (abt. kg) 28 50 87 160 185 355
Shielding gas equipment • • •
Stud counter -
Interface for automatic components -
Stud welding guns: SK 14 • •
K 22 •
K 22-D •
K 24 - - - - •
K 26 - - - - - •
S Welding under increased electrically hazardous conditions permissible, CE-Labelling according to EN 60974-1 etc.
10
KÖCO – Stud Welding Guns
CLASSIC
The CLASSIC series of stud The precision technology movement when it plunged
welding guns are techno- of KÖCO stud welding guns into the welding pool (recom-
logically advanced high ensures repeatability and mended for welding studs
performance tools for drawn produces first-class welding approx. 14 mm ø).
arc stud welding. They are results, even under difficult
designed for comfortable operating conditions. All guns are compatible with
operation and known for their most commercially available
sturdiness and reliability. The An adjustable hydraulic stud welding systems.
range includes guns for every plunge damper is standard
application, matching acces- in the K 22-D, K 24 and
sories are available. K 26 guns, to damp the stud
11
KÖCO – Stud Welding Guns
SERIES CLASSIC
Technical data SK 14 K 22 K 22-D K 24 K 26
Stud welding with ceramic ferrule
Lifting range from ... to ... (mm) 1 - 4.5 1 - 4.5 1 - 4.5 2.5 - 6 2.5 - 6
Body:
Weight excluding cables app. (kg) 0.9 1.3 1.3 1.4 2.6
12
HEADED CONCRETE ANCHOR
General Purpose Studs used for other than shear transfer in composite beam design and
construction.
DIMENSIONS IN MILLIMETRES
FERRULE
13
HEADED SHEAR CONNECTORS
Headed Shear Connector are used as an essential component in composite beam design
and construction.
NOTE: L = manufactured length before welding
Shank Diameter Length (L) Head Diameter Minimum head
(d) tolerance tolerance height HT
19.0 +0.00 ±1.6 31.7±0.4 9.5
-0.38
22.2 +0.00 ±1.6 34.9±0.4 9.5
-0.38
DIMENSIONS IN MILLIMETRES
MATERIAL LOW CARBON STEEL
AS1445 S1010 to S1020
or K1010 to K1020
MECHANICAL Tensile....................................410MPa (min)
PROPERTIES Yield........................................345MPa (min)
Elongation...............................................12%
Reduction of area......................50% (min)
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.
14
Headed Concrete Anchors and Shear Connectors
Standard Sizes
(Dimensions in millimeters)
CONCRETE ANCHORS
Part Number Size Weight Ea Pack Qty
SC11-13-050 12.7 x 50 .079 250
SC11-13-075 12.7 x 75 .104 150
SC11-13-100 12.7 x 100 .129 125
SHEAR CONNECTORS
Part Number Size Weight Ea Pack Qty
SC11-19-075 19 x 75 .217 100
SC11-19-095 19 x 95 .259 75
SC11-19-100 19 x 100 .271 75
SC11-19-105 19 x 105 .281 75
SC11-19-115 19 x 115 .303 60
SC11-19-120 19 x 120 .313 60
SC11-19-125 19 x 125 .329 60
SC11-19-150 19 x 150 .379 50
SC11-19-175 19 x 175 .441 45
SC11-19-200 19 x 200 .485 40
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
15
ARC STUD WELD INSPECTION (VISUAL)
16
COMPOSITE-BEAM CONSTRUCTION
Even without the use of metal As stated, these benefits are You build better. Metal deck
decking, composite beam attainable whether you use provides restraint for supporting
construction is, in several metal deck or through-deck members, stiffening the structure
ways, superior to slab-on-beam welding. Consider, however, and giving better load distribution.
construction. how much better composite The deck minimises deflection,
Composite design reduces steel beam construction is when you reducing the amount of concrete
weight. DO use metal deck and ARCFIX needed. The concrete, itself, is
through-deck welding. better because the steel retains
Live load deflection is reduced hydration needed for proper
because of the concrete’s mass The job costs less. You don’t
have to erect wood forms curing. You’ll have fewer cracks,
and thickness and the steel easier inspection.
beam’s depth. then strip them away, then re-
erect them. The metal deck You build safer. The metal
Overall building height can be which provides a permanent deck provides a safer, more
reduced because the beams are form for the concrete, can also stable platform for workmen
shallower – saving on heating, incorporate cellular sections for of all trades. Metal deck also
air-conditioning and exterior and electrical cables. Ceilings are eliminates a major construction
interior wall costs. easier to hang. headache – fire in the forms
Longer spans can be used with and shoring. Insurance rates are
fewer columns, beams and usually lower.
connections. The results are These are typical of the benefits
larger rooms, more useable bay you can look for in composite
area, and more flexible floor beam/weld-through metal deck
plans. The structure goes up construction. Actual savings will,
faster; fabrication costs come of course, vary with the job.
down.
17
CONSUMABLES
18