There are nearly a dozen different methods for mounting anchor points on a surface with stud welding, each with their own benefits and challenges. Friction stud welding is a powerful technique that works well for assembly processes of all types and sizes. Find out why this advanced stud welding equipment is worth investing in to expand your welding business.
Consider how the environment of the stud weld affects the finished product. In your usual arc welding systems, the gases and electrical arcs both contribute to unwanted elements like hydrogen getting mixed into the weld pool. The metal softening effect of friction works differently. Instead of melting the metal and plunging in the stud, the metal of both the stud and the surface becomes soft and merges without liquefying.
A firmer weld pool results in cleaner, more even results no matter how many studs are installed in the project. If you are trying to get framing or foundation beams installed on a tight deadline without the extra time for a lot of quality control, the reliability of friction stud welding speeds up the process significantly for both you and your client. You can even skip the surface preparation step in many situations involving paint, rust, or corrosion, further cutting down on prep time.
More Challenging Environments
Want to take on stud welding jobs with flammable gases in the work area or corrosive coatings on the metal, like salt deposits on an offshore oil rig? The buffing effect of the friction welding rotation makes it ideal for using in challenging assembly and building environments like
- Underwater support structures for research platforms, and offshore wind farms
- Storage and containment areas for hazardous chemicals and gases
- Dusty and dry environments with particulate in the air that could ignite if live sparks and gases are used in the welding process.
While friction stud welding first proved its value in the underwater welding world, it's now used widely above the water too because of its versatility in different situations. You don't need to be an underwater welding specialist to use it.
With the right equipment, it only takes about four seconds for the metal to spin and generate enough heat to create a permanent attachment point. Getting each stud weld done as quickly as possible doesn't just save you time on construction. Faster weld techniques also reduce issues with cooling, since the metal reaches temperature and drops down again faster. Friction techniques eliminate the plunging step of the stud welding process, ensuring the stud piece is in place at the perfect moment for welding.
Reduced Resource Demands
Trying to position your welding services as eco-friendly? Friction welding is particularly friendly to the environment because it's inherently low waste. There's no reject metal left over after each join, except for the tiny flakes of residue ash that form when working on a dirty surface. With no gas or high electrical loads to power the stud process, the project is completed with fewer resources, which also boosts your profit margin.
Wider Compatibility Ranges
Finally, don't forget about the ability to bond specific and dissimilar metals together with fast spinning friction stud welding. If your client needs copper studs for conduction but wants to use a mild steel base, the application of friction can force the two metals to bond evenly. You'll get good results as long as you follow the requirements for pressure and rotations per minutes based on the combination you're making.
Friction stud welding systems do cost more than other forms of arc-based alternatives, but it's worth the cost for welding companies trying to stay agile and invest in cutting edge technology. The improved welding results, especially in unusual circumstances and environments, pay off handsomely in the long run. For more information about stud welding systems, check out a company like Northland Fastening Systems.