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Drawn arc stud welding is an economical joining process for joining pin-shaped components (studs) with diameters ranging from 2 to 22 mm to sheet metal, profiles or pipes. As a result of irregularities in the welding …
Drawn arc stud welding is an economical joining process for joining pin-shaped components (studs) with diameters ranging from 2 to 22 mm to sheet metal, profiles or pipes. As a result of irregularities in the welding and movement sequence, faulty welded joints and limitations in load-bearing capacity are repeatedly observed in practice. The aim of the research project was to develop new concepts for welding guns with improved lift and immersion behaviour and to develop suitable measuring devices to make it easier to detect and correct faults in the device or its settings. To solve this task, a pneumatically and a mechanically-magnetically operated system, each with stud length compensation, were developed and tested as new movement concepts for drawn arc stud welding.
Both motion sequences fulfil the requirements for the repeat accuracy of lift and penetration in equal measure. With the mechanical-magnetic movement sequence, the feasibility of a completely new welding gun concept was successfully demonstrated. The movement sequence can be precisely maintained with these guns. Concepts and practical measuring devices have been developed and tested for monitoring the welding process, which, by observing the current, welding time, arc voltage, lift height and immersion depth, can recognise incorrect welding settings or execution. The stud welding process is used by many small and medium-sized companies due to its simple handling and low equipment costs. At a time of new European quality assurance systems and product liability laws, the research results have met with great interest from these companies in particular. This has led, among other things, to suggestions from this work being taken up by appliance manufacturers during the realisation of the research project and taken into account in the development of new appliance concepts. STUDIENGESELLSCHAFT STAHLANWENDUNG e.V.
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