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Diagnosis of Stud Welding Difficult and Miscellaneous Disorders
Release time:
2021-09-27
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Welding experts combined with 40 years of stud welding experience, put forward detailed solutions to some stud welding intractable diseases, and solve the stud welding production problem in your production! 1. For this welding position, due to gravity, the dissolved metal tends to flow to the lower side of the bolt during welding, resulting in uneven weld angle formation. The larger the bolt diameter, the greater the impact. Generally speaking, for this reason, vertical welding of bolts with a diameter of more than 10mm is not recommended. To obtain a satisfactory fillet forming basic requirements set the shortest welding time. A vertical weld will reduce the maximum size of the weld bolt for a given power source. must bear in mind
Welding experts combined with 40 years of stud welding experience, put forward detailed solutions to some stud welding intractable diseases, and solve the stud welding production problem in your production!
1. vertical welding
For this welding position, during welding, due to gravity, the dissolved metal tends to flow during welding.The underside of the bolt causes uneven weld fillet formation. The larger the bolt diameter, the greater the impact. Generally speaking, for this reason, diameter is not advocated.10MMThe above bolts shall be subjected to vertical welding. To obtain a satisfactory fillet forming basic requirements set the shortest welding time. A vertical weld will reduce the maximum size of the weld bolt for a given power source.
It must be borne in mind that special care is taken to ensure that the bolt is perpendicular to the workpiece. Upon request, Taylor can provide specially made foot attachments. Special attention should be paid to keep the porcelain ring jacket and the bolt jacket of the foot seat clean.
2. overhead welding
When performing overhead welding, wear a protective cover to protect the face and shoulders, because welding slag can cause damage.
First, before the overhead welding, the welding settings are made under manual control. When welding under the hand position, the weld metal flows from the bolt to the plate in the form of small particles. But in overhead welding, it will flow against gravity. Therefore, for overhead welding, to achieve the best results, the shortest welding time needs to be used.
Special attention should be paid to keep the porcelain ring jacket and the bolt jacket of the foot seat clean to prevent the welding slag from falling on the surface of the workpiece.
3.Torch adjustment during vertical welding or overhead welding
Problems may be encountered when using a damping (snubber) torch for vertical or top-of-head welding.
To prevent problems, remove the damping effect.When the shock absorber is removed, the lock nut of the decelerator is removed, and the nut on the front end cover is loosened2mmleft and right, thenRe-tighten the lock nut.
4.Cable lengthening
Often used welding torches are often some distance from the nearest power supply. For example, welding on prefabricated steel structures in ship decks, power plants, building structures, and workshops. For these cases, an extended welding cable is required. However, it must be recognized that the longer the cable, the smaller the maximum diameter of the welding bolt under a given power source.
In order to solve this problem, such as the use of extended cable welding larger diameter bolts, to increase the size of the welding cable wire or parallel cable.
5.Porcelain ring protection welding length shorter25mmBolt
Bolts are required to be clamped in their jacket grooves and have enough length to allow us to set the correct extension. Standard bolt jacket has12mmDeep groove, its porcelain ring jacket length up13.5mm. Thus, if the bolt length is shorter25mm, It is difficult for us to obtain the correct bolt extension head, that is, the bolt jacket may hit the porcelain ring jacket during retensioning to prevent the bolt from returning to the board correctly.
This problem can be solved by using a "shallow groove" jacket (groove depth only6mm) Or if the bolts to be used are very short, special "break" bolts can be used. Overall length of the bolt30mm, And use standard bolt jacket and porcelain ring jacket. The bolt is easily broken at the required length from the welding end. After welding, the excess part of the bolt can be easily disconnected with pliers. Using this method, it is easy to weld very short bolts.
6. Use touch plate tooling to ensure correct positioning
When welding on the periphery of the flange, such as cover plate, inspection door, etc., the positioning of the bolts between each other is very important. The solution to this problem is usually2mmThe thick board is cut into simple tooling that matches the parts and is equipped with fixtures. On the plate, accurately mark the bolt positions and drill holes in these positions to enable the insertion of the bolt's porcelain ring jacket or (short cycle equipment) torch gas jacket. The size of the hole should be the diameter of the porcelain ring jacket/gas sleeve.0.4mm. It is recommended to fit the lower part of the tooling.2mmThe thick gasket allows a gap between the component and the tooling. This gap allows the porcelain ring jacket/air jacket to be well ventilated during welding. If you need advice on tooling or fixture design, please contact your local Taylor sales engineer.
7 Minimum thickness of workpiece required for bolt welding
When using standard arc drawing equipment protected by porcelain ring, the thickness of the plate is greater3mmThe minimum ratio of bolt diameter to plate thickness is4：1Plate thickness1.5-3mmWhen3：1. Due to the short welding cycle, almost the same size bolts can be welded to relatively thin plates using gas-shielded or non-gas-shielded short-cycle welding.
These proportions ensure that the plate is strong enough to support the bolt loads and that the plate is not deformed.
However, occasionally welded bolts may exceed this ratio. At this time, a copper plate or water-cooled support is usually placed under the welding area to support the support plate to help quickly dissipate heat so that the heat penetration part will not deform.
8. Welding stainless steel
18/8 g/NOlympic-type stainless steel bolts: capable of welding similar carbon steel with anti-decay type. The technique is no different from carbon steel bolt welding. It tends to have large diameter stainless steel bolts because of its metal flow through the welding arc into large particles. If a short circuit occurs, you will hear the welding arc crackling.
If the gun lift is not adjusted correctly, this can occur when welding bolts of any diameter. Since it tends to flow with large particles, the time setting should be as small as possible
9. Welding near corners, flanges and other obstacles
When welding near the plate edge, corner and narrow plate, occasionally "magnetic bias blowing" effect will lead to uneven welding angle.For this fillet condition, most of the material is deflected to the bolt side.
"Magnetic blow" is caused by the electromagnetic force around a strong welding arc in one direction due to the presence of an air gap or an approximate bulk magnetic material. It is affected by many factors, such as bolt size, component shape, ground connection position and current. There is no shortcut to solving it. The following methods often help to solve this problem. If you are still not satisfied with the results, our Taylor engineers are happy to help you.
Before judging the uneven welding angle caused by "magnetic bias blowing", weld some bolts on the test plate to check whether there are other errors.
Sometimes the method of correcting "magnetic blow" is to place a piece of steel on the welding area on the opposite side of the blow corner. When welding near the plate edge, the weld angle is biased towards the bulk material, I .e. away from the edge. The steel blocks shall be placed at the edges of the plates and in contact with each other to form a uniformly distributed magnetic field. The position of the grounding under the bolt welding position shall be adjusted. The latter is not very useful due to the frequent movement of the ground.
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Key words:
Diagnose, weld, bolt, use, diameter, cable, due, location, solve, problem
