WO2005051587A1 - Welding stud - Google Patents
Welding stud Download PDFInfo
- Publication number
- WO2005051587A1 WO2005051587A1 PCT/US2004/036442 US2004036442W WO2005051587A1 WO 2005051587 A1 WO2005051587 A1 WO 2005051587A1 US 2004036442 W US2004036442 W US 2004036442W WO 2005051587 A1 WO2005051587 A1 WO 2005051587A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- stud
- welding
- welding stud
- weld
- workpiece
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/20—Stud welding
- B23K9/207—Features related to studs
- B23K9/208—Ferrules, e.g. for confining molten material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
- B23K35/0288—Welding studs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/20—Stud welding
- B23K9/207—Features related to studs
Definitions
- the present invention relates generally to welding systems and, more particularly, to a welding stud for stud welding applications.
- Stud welding is a welding process that utilizes a localized burst of current between a metallic fastener and a metallic workpiece.
- a stud welding system has a power source, a stud gun, a pair of cables that connect the stud gun to the power source, and a stud that is welded to a workpiece.
- the fastener and the workpiece have the same material properties.
- the fasteners are held and welded in place through the use of an electro-mechanical device in the stud gun.
- Stud welding has applications in many industries. These industries include boiler manufacturing, ship building, auto manufacturing, and construction to name but a few. Welding a stud to a workpiece is an easy and efficient means of securing a fastener device to the workpiece. Studs are also provided in a variety of shapes and materials such that welding studs to a workpiece can be used to differentiate between further systems to be attached to the workpiece depending on the type of stud welded thereto.
- the quality of the weld which attaches the stud to the workpiece partially determines the amount of load the stud can support.
- a poor quality weld can result in failure of the weld between the stud and the workpiece.
- Weld failure associated with poor weld quality is difficult to predict and is often designed around by over welding the stud rather than improving the welding efficiency of the weld stud.
- a low efficiency in the stud welding process is partially due to low, effective contact resistance between the stud and a workpiece.
- the efficiency of the weld between the stud and the workpiece is partially determined by the physical construction of the welding stud used and the condition of the interface between the welding stud and the workpiece.
- a poor interface between the welding stud and the workpiece detrimentally affects arc performance and can result in weld failure.
- the physical construction of the weld end of the welding stud also affects the quality of a weld between a welding stud and a workpiece. If the weld end of the welding stud is poorly constructed, an incomplete weld can be formed between the welding stud and the workpiece after the termination of the welding process.
- a welding stud and method of manufacturing a welding stud are disclosed that include at least one ridge, but preferably, a plurality of ridges formed in the weld end of the welding stud.
- the plurality of ridges localize a current passed through the weld end of the welding stud during a welding operation. By localizing the current through the weld end of the stud, the stud can be welded to a workpiece faster and with lower energy than welding studs without the current localizing construction of the invention.
- a welding stud which has a body extending between a first and a second end.
- the first end is constructed to engage a stud welding gun.
- At least one recess is formed in the second end that increases the effective surface area of the second end and is designed to decrease an effective arc area of the second end.
- a welding stud having a body having a body.
- the body extends from a connector end constructed to engage a stud welding gun.
- a weld end of the welding stud, opposite the connector end, has at least one protrusion and is constructed to be welded to a workpiece.
- the protrusion extends outwardly to space a majority of the weld end having a non-planar surface from a workpiece.
- Such a construction reduces the cross-sectional area of the weld end and localizes current passing therethrough during a welding operation.
- a method of manufacturing a welding stud is disclosed.
- the method includes providing a welding stud having a first end and a second end, forming the first end to engage a stud welder, and forming the second end with increased resistance to current flow as compared to a welding stud having a nipple and a generally planar surface thereabout.
- a welding stud has a first end constructed to engage a stud welding gun.
- a body extends from the first end to a face of a weld end.
- the welding stud includes means for localizing current density in the face of the weld end of the welding stud.
- FIG. 1 is a perspective view of a stud welder apparatus according to the present invention.
- Fig. 2 is a side view of the stud welding gun of Fig. 1 in use.
- Fig. 3 is a perspective view of a welding stud in accordance with the present invention that may be used with the stud welder shown in Fig. 1.
- Fig. 4 is a cross-sectional view of a weld end of the welding stud shown in Fig. 3.
- Fig. 5 is a plan view of the weld end of the welding stud shown in Fig. 4.
- Fig. 1 is a perspective view of a stud welder apparatus according to the present invention.
- Fig. 2 is a side view of the stud welding gun of Fig. 1 in use.
- Fig. 3 is a perspective view of a welding stud in accordance with the present invention that may be used with the stud welder shown in Fig. 1.
- Fig. 4 is a cross-sectional
- FIG. 6 is a cross-sectional view of the weld end of an alternate embodiment of a welding stud in accordance with the present invention.
- Fig. 7 is a plan view of the weld end of the welding stud shown in Fig. 6.
- Fig. 8 is a cross-sectional view of the weld end of another alternate embodiment of a welding stud in accordance with the present invention.
- Fig. 9 is a plan view of the weld end of the welding stud shown in Fig. 8.
- Fig. 10 is a cross-sectional view of the weld end of yet another alternate embodiment of a welding stud in accordance with the present invention.
- Fig. 11 is a plan view of the weld end of the welding stud shown in Fig. 10.
- Fig. 12 is a cross-sectional view of the weld end of another alternate embodiment of a welding stud in accordance with the present invention.
- Fig. 13 is a plan view of the weld end of the welding
- Fig. 1 shows a stud welding system 10 in accordance with the present invention.
- Stud welding system 10 includes a housing 12 enclosing the internal components of the welding power source such as a circuit board and power source.
- the stud welding device 10 is of such compact construction that it includes a handle 14 for easily transporting the welding system from one location to another.
- the stud welding device 10 includes a stud welding gun 16 as well as a work clamp 18.
- the work clamp 18 is configured to complete the welding circuit to a workpiece 20 to be welded.
- Connecting the stud welding gun 16 and work clamp 18 to the housing 12 is a pair of cables 22 and 24, respectively.
- a stud 21 Prior to a welding operation, as shown in Fig. 2, a stud 21 is placed in a work end 26 of stud welding gun 16 and in abutting engagement with workpiece 20.
- a trigger 17 of stud welding gun 16 When a trigger 17 of stud welding gun 16 is pressed, a welding current is developed between the welding gun 16 and workpiece 20 through stud 21.
- An arm 28 of stud welding gun 16 is used to accommodate stud 21 and allow drawing stud 21 away from workpiece 20 to form a stud welding arc.
- the welding arc is formed upon drawing the stud 21 from the workpiece 20 as an electrical current 32 passes through stud 21 and workpiece 20.
- electrical current 32 passes through stud 21 and workpiece 20.
- a weld end 34 of stud 21 and a target point 36 of workpiece 20 become molten.
- An inner collet 38 of stud welding gun 16 maintains a distance, indicated by arrows 39, between stud 21 and workpiece 20 during the welding process.
- Distance 39 is determined to be the distance required to form a proper welding arc between stud 21 and workpiece 20.
- stud 21 is driven into workpiece 20, thereby forming a homogenous weld between stud 21 and workpiece 20.
- Welding stud 21 includes a body 40 disposed between weld end 34 and a gun end 42.
- Gun end 42 is constructed to engage a stud welding gun as shown in Fig. 2. Additionally, gun end 42 can be constructed to engage a connector (not shown) after welding stud 21 has been welded to a workpiece.
- gun end 42 of stud 21 includes a head 44 formed thereabout. It is understood that head 44 could be of many shapes depending on the stud gun used and the ultimate application of the stud. Head 44 only needs to be constructed to engage the work end of the stud welding gun and adaptable to provide a further connection thereto.
- weld end 34 of welding stud 21 has a plurality of ridges 46 formed thereon and concentrically orientated about a center axis 48 of welding stud 21.
- a groove 50 is formed between adjacent ridges 46.
- a nipple 52 is formed in the center of weld end 34 and is surrounded by a face 54 of weld end 34 of welding stud 21.
- a majority of weld end 34 is occupied by face 54 with nipple 52 positioned in the center thereof.
- face 54 has a substantially non-planar construction, which provides for localized current density during a welding process. Face 54 decreases an effective arc area between welding stud 21 and workpiece 20.
- a welding arc is formed as electrical current passes between weld end 34 of welding stud 21 and workpiece 20.
- the non-planar construction of face 54 results in an increase in effective surface area of weld end 34 and provides a stud with a decreased contact area.
- the contact area being defined as that area that would contact a workpiece once plunged into the workpiece during the welding process.
- grooves 50 formed in weld end 34 of welding stud 21 increase the total surface area of face 54 and reduce the cross-sectional surface area of the face. As such, grooves 50 decrease the effective arc area, between welding stud 21 and a workpiece.
- Ridges 46 extend to a tip 56 at face 54 and encircle nipple 52 and define the contact surface between welding stud 21 and a workpiece.
- Face 54 extends along weld end 34 from nipple 52 to an outer surface 58 of welding stud 21.
- nipple 52 ensures adequate separation between face 54 and a workpiece prior to initialization of the welding process. Once the welding process is initiated, nipple 52 and tips 56 are liquefied.
- Grooves 50 focus the current traveling through face 54 and a workpiece at tips 56 of ridges 46. Such a construction creates a localized current density on face 54 that is higher than a local current density of a welding stud with a substantially planar welding face. As ridges 46 and nipple 52 are liquefied during the welding process, grooves 50 decrease until the stud and workpiece become one.
- ridges 56 and grooves 50 are positioned generally circumferentially about nipple 52 on weld end 34 of welding stud 21. Ridges 56 and grooves 50 also extend generally uniformly from nipple 52 to outer surface 58 of welding stud 21.
- welding face 54 is geometrically centered about the longitudinal axis 48, shown in Fig. 3, of welding stud 21. Such a construction ensures a generally uniform arcing about face 54 of welding stud 21, after nipple 52 is liquefied, during a welding process.
- the increased resistance associated with welding stud 21 ensures uniform welding of studs to a workpiece in a repeatable and efficient manner, thereby creating an efficient weld process.
- FIG. 6 An alternate welding stud 60 is shown in Figs. 6 and 7.
- Welding stud 60 is similar to welding stud 21 in that it includes a plurality of ridges 64 and a plurality of grooves 66 disposed about a nipple 68 on a weld end 62 of welding stud 60.
- Grooves 66 do not extend as deeply into weld end 62 of welding stud 60, Fig. 6, as grooves 50 extend into weld end 34 of welding stud 21, Fig. 4, however, weld end 62 has a tapered perimeter 70. Tapered perimeter 70 reduces the effective surface area of weld end 62 to a workpiece during a welding process. As shown in Fig.
- weld end 62 of welding stud 60 is similar to weld end 34 of welding stud 21 shown in Fig. 5 in that both weld end 34 and 62 have a plurality of generally concentric grooves and ridges about a nipple.
- Tapered perimeter 70 of weld stud 60 reduces the effective cross-sectional area of weld end 62 during a welding process. Tapered perimeter 70 and grooves 66 each contribute to concentrate a current passed through weld end 62 of welding stud 60 at ridges 64. As such, after a welding process is initiated and nipple 68 is liquefied, the welding current is localized, or concentrated, at ridges 64.
- a welding stud 80, Figs. 8 and 9, and another welding stud 100, Figs. 10 and 11, have a pattern formed in the welding end based on a relatively simple geometric pattern.
- Welding stud 80, shown in Figs. 8 and 9, has a cross-sectional shape that is similar to the cross-sectional shape of welding stud 21, as shown in Fig. 4.
- a nipple 82 is positioned on a center axis 84 of a weld end 86 of welding stud 80.
- a plurality of grooves 88 and a plurality of ridges 90 are formed in a face 92 of weld end 86. Face 92 extends from nipple 82 to a perimeter 94 of weld end 86 of welding stud 80.
- Fig. 9 shows the generally geometric pattern formed in weld end 86 by the plurality of linear grooves and ridges.
- Welding stud 100 shown in Figs. 10 and 11, has a plurality of recesses 102 formed between a plurality of adjacent ridges 104. Recesses 102 and ridges 104 are formed on a face 106 of a weld end 108 of welding stud 100.
- a nipple 110 extends past face 106 along an axis 112 of welding stud 100 and initiates the contact of welding stud 100 with a workpiece.
- a taper 114 can be formed about a perimeter 116 of face 106 of welding stud 100 to reduce the effective cross-sectional area of weld end 108 of welding stud 100.
- a welding stud having a non-planar face between the nipple and the perimeter of the welding end of the welding stud Regardless of the pattern formed on the face of the weld end, a welding stud having a series of ridges and grooves formed in the face of the welding end is more efficiently welded to a workpiece than a welding stud with a generally planar face.
- the non-planar face provides for localized current density at the ridges during the welding process. Localizing the current increases the efficiency with which the welding stud can be welded to a workpiece.
- each of the geometric patterns yield a welding stud which benefits from localized current densities during a welding process.
- the patterns shown in the figures are merely by way of example and in no way limit the claims herein. It is equally understood that the patterns of grooves and ridges formed in the faces of the welding studs disclosed herein could be by any one of etching, stamping, machining, etc.
- a flux capsule 122 or a combination of powered metal and flux, is enclosed in the weld end 124 of welding stud 120.
- a contact tip 126 of flux capsule 122 functions similar to the nipple of the previous embodiments and extends past a face 128 of weld end 124 of welding stud 120.
- Contact tip 126 of flux capsule 122 is constructed to initiate contact with a workpiece during a welding operation.
- flux capsule 122 inhibits atmospheric contaminants from polluting the pool of molten weld material generated during the welding process. As such, flux capsule 122 ensures a high quality, unpolluted weld between stud 120 and a workpiece.
- Face 128 extends between a perimeter 130 of flux capsule 122 to a tapered perimeter 132 of weld end 124 of welding stud 120.
- the current across welding stud 120 is localized at face 128 of welding stud 120.
- welding stud 120 localizes a welding current at face 128 after the initialization of the welding process that liquefies flux capsule 122. It is understood that flux capsule 122 could be incorporated into any/each of the previously disclosed welding studs in order to achieve the benefits of having a flux introduced into a weld.
- a decrease in the amount of energy needed to weld a stud of a given diameter can be achieved when compared to the amount of energy required to weld a stud having a nipple and a generally planar face.
- the energy decreases result from a higher current density through the weld stud of the workpiece.
- the path of least resistance extends through the metal portion of the stud around the flux capsule.
- the flux capsule by having a relatively high electrical resistance, allows relatively low levels of current to flow through it. This results in increased current density in the metal portion of the stud around the flux capsule. This construction requires lower energy levels for welding.
- the flux capsule could be replaced with powdered metals. Similar to the flux capsule, the powdered metals results in a decrease in the amount of energy required to weld a given stud diameter when compared to a stud with a nipple and planar face.
- the powered metal capsule has a relatively high electrical resistance compared to the solid metal portion of the stud extending therearound. The energy decreases result from the relatively high current density through the solid metal portion of the stud and thereby around the powdered metal capsule. Such a construction results in increased local current densities which provides for efficient welding with lower energy.
- Each of the embodiments of the present invention realize the benefits achieved by a welding stud having a generally non-planar weld end.
- the non-planar face of the weld end results in decreased contact area between the welding stud and a workpiece during a welding process, an increase in the total surface area of the weld end, and provides localized current density during a welding process.
- a welding stud constructed according to the invention requires less energy to weld the stud to a workpiece compared to a welding stud having a generally planar face.
- a welding stud has a body extending between a first and a second end.
- the first end is constructed to engage a stud welding gun and the second end has at least one recess formed therein.
- a welding stud has a body extending from a connector end constructed to engage a stud welding gun.
- the welding stud has a weld end having at least one protrusion and is constructed to be welded to a workpiece.
- the protrusion extends outwardly to space a majority of the weld end having a non-planar surface from a workpiece.
- a method of manufacturing a welding stud includes providing a welding stud having a first end and a second end, forming the first end to engage a stud welder, and forming the second end with increased resistance to current flow as compared to a welding stud having a nipple and a generally planar surface thereabout.
- a welding stud has a first end constructed to engage a stud welding gun.
- a body extends from the first end to a face of a weld end.
- the welding stud includes means for localizing current density in the face of the weld end of the welding stud.
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP04819514A EP1699588A1 (en) | 2003-11-26 | 2004-11-02 | Welding stud |
CA2546240A CA2546240C (en) | 2003-11-23 | 2004-11-02 | Welding stud |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/707,214 | 2003-11-23 | ||
US10/707,214 US7452171B2 (en) | 2003-11-26 | 2003-11-26 | Welding stud |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2005051587A1 true WO2005051587A1 (en) | 2005-06-09 |
WO2005051587A8 WO2005051587A8 (en) | 2007-09-27 |
Family
ID=34590835
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2004/036442 WO2005051587A1 (en) | 2003-11-23 | 2004-11-02 | Welding stud |
Country Status (4)
Country | Link |
---|---|
US (1) | US7452171B2 (en) |
EP (1) | EP1699588A1 (en) |
CA (1) | CA2546240C (en) |
WO (1) | WO2005051587A1 (en) |
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DE102009020080A1 (en) * | 2009-05-06 | 2010-11-11 | Newfrey Llc, Newark | Joining component and fastening arrangement |
DE102010013229A1 (en) * | 2010-03-29 | 2011-09-29 | Ejot Gmbh & Co. Kg | Connecting element for a friction-welded connection for connecting at least two plate-like components |
DE102011076261A1 (en) * | 2011-05-23 | 2012-11-29 | Ford Global Technologies, Llc | Welding pin having a variable, head-side functional area |
US10265796B2 (en) * | 2011-11-17 | 2019-04-23 | Nelson Stud Welding, Inc. | Adaptively controlled short circuiting drawn-arc fastener welding |
WO2014163677A2 (en) | 2013-03-13 | 2014-10-09 | Rolls-Royce North American Technologies, Inc. | Retention pin and method of forming |
US9752607B2 (en) | 2013-03-13 | 2017-09-05 | Rolls-Royce North American Technologies, Inc. | Retention pin and method of forming |
DE102013225048A1 (en) * | 2013-12-05 | 2015-06-11 | Bayerische Motoren Werke Aktiengesellschaft | Bolt element and welding method for connecting this bolt element with a workpiece |
CN106163721B (en) * | 2014-02-03 | 2021-10-15 | 豪梅特航空航天有限公司 | Resistance welding fastener, apparatus and method |
CN103982506B (en) * | 2014-05-16 | 2016-06-08 | 深圳大学 | A kind of welding quality that is effectively improved is held concurrently the peg shear connector of ductile fracture feature |
EP3354393B1 (en) * | 2017-01-30 | 2023-09-06 | Newfrey LLC | Welding element and welding method for connecting a welding element with a workpiece |
EP3466590A1 (en) * | 2017-10-09 | 2019-04-10 | HILTI Aktiengesellschaft | Fixing method |
CN108412872A (en) * | 2018-05-11 | 2018-08-17 | 中国铁道科学研究院集团有限公司 | Rivet |
CN113600982B (en) * | 2021-07-22 | 2022-11-11 | 中国航空制造技术研究院 | Screw for stud welding and welding device |
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- 2004-11-02 WO PCT/US2004/036442 patent/WO2005051587A1/en active Application Filing
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Also Published As
Publication number | Publication date |
---|---|
CA2546240A1 (en) | 2005-06-09 |
WO2005051587A8 (en) | 2007-09-27 |
US7452171B2 (en) | 2008-11-18 |
EP1699588A1 (en) | 2006-09-13 |
US20050111932A1 (en) | 2005-05-26 |
CA2546240C (en) | 2010-09-14 |
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