At present, in the body connection, everyone pays attention to the process of directly connecting two or more (such as SPR in the cold connection, FDS, etc., spot welding in the thermal connection, laser welding, etc.), but in the body design, through The role of the studs in indirect connection is also very important. It can be seen everywhere in the body-in-white, through which he achieves indirect connections and provides installation for other components.
Body stud welding diagram
Process introduction
Stud welding means that one end of the stud is in contact with the surface of the workpiece to be welded (plate or pipe), and an arc is generated between the two. When the surface to be joined is melted, a certain pressure is applied to the stud and rapidly squeezed together to form Welds, a process that forms a strong connection.
The stud welding process has many advantages such as fast and reliable , simplified , easy to operate , and low cost . At present, the role of the stud in the compartment is to fix the wiring harness, interior parts and carpet; the role outside the compartment is to fix the harness, tubing, brake Tubing accessories such as oil pipes and heat shields and deflectors.
Stud welding is divided into arc-type stud welding and energy storage stud welding
The arc-arc stud welding machine is a small current arc-starting arc generated by the machine when the stud is welded. After this small current burns and removes various attachments on the surface of the welding base material, the machine is again A welding method that produces a large current and welds the stud to the base metal.
The arc-arc stud welding machine can be divided into short-period arc and long-period arc according to the length of time required for the welding process.
Short cycle arcing , that is, welding time is short, generally within 200 milliseconds, suitable for welding between thin plates (below 5mm) and smaller diameter (less than 10mm); long period of arc welding has a longer welding cycle. Up to 2000 milliseconds, suitable for welding between plate thickness (more than 2mm) and larger diameter (10mm or more).
Pull-arc stud welding step-by-step diagram
Internal drawing of arc-arc stud welding operation
The working principle of the energy storage stud welding machine is: input a single current of 220V, first store energy by capacitor, then control the capacitor discharge by the control system, the voltage of the discharge can be adjusted according to the welding needs, discharge in the capacitor Instantly, the studs mounted on the welding gun are welded to the base metal.
Energy storage stud welding profile
Internal view of energy storage stud welding operation
Special feature
Since the energy of arc combustion during stud welding is concentrated between the stud and the base metal, there is no excess energy loss, and the welding process is simple and reliable, especially the arc-arc stud welding of ceramic ring protection, and its characteristics are summarized as follows What time is it:
Ø No drilling is required when welding the surface of the workpiece, and no leakage will occur.
Ø Stud welding head has high strength and meets or exceeds the strength of the base metal.
Ø After the plating or high-alloy coffin is welded, there is no imprint on the back.
Ø High welding efficiency, in general, at least 6 screws can be welded per minute.
Ø Less investment in materials and equipment.
However, stud welding should pay attention to the limitation of carbon content in steel in applications. For structural steel studs, the carbon content w(c) should be within 0.18%, and for the parent metal should be within 0.20%.
Many users cannot meet the post-weld strength requirements. In addition to the process factors, the materials of the screws and base metals are also a major cause.
The difference between the arc type and the energy storage type stud welding
1. The welding nail used in the arc-arc stud welding is an ordinary welding nail, and the welding nail material is required to be the same or close to the base material. The welding end surface of the rivet has a taper of 3 to 5 degrees, and the capacitive energy storage stud welding In addition to the material and the welding nail end face requirements are the same as the drawn arc stud welding, it also requires a 0.8*0.8 arcing point on the end face of the welding pin.
Energy storage stud pull arc stud
2. The diameter requirements of the welding nails are different. The energy storage stud welding is generally used for welding studs with a diameter of 3-10 mm, and the arc-studded stud welding has a diameter of 3-25 mm.
3. The requirements for the surface of the welded base metal are different. The arc-type stud welding is not strict with the welding base material, as long as the surface of the welded base metal can be electrically conductive, even if the surface of the welded surface is slightly rusted, oily, metal-plated, and other impurities. Affecting welding and energy storage stud welding requires strict requirements on the base metal. The poor surface of the base metal will lead to an increase in electrical resistance, and it is impossible to weld the live welding. If the coating is thick, it will be difficult to weld.
Energy storage physical map
There is no obvious damage on the surface of the plate around the storage studs; there is no obvious mark on the back of the plate, and the welding around the front of the arc-type stud welding is black and cannot be erased; there is a certain deformation on the back.
4. The melting depth of the two is different. The arc welding of the arc-type stud welding is deep. The short-cycle welding depth is generally not more than 0.1, the long-period welding depth is generally greater than 0.3, and the arc-arc stud welding will be welded. Regular welds are formed around the studs to enhance strength. The energy storage studs are shallower and shallower, generally less than 0.2.
Through the above introduction, we have learned the difference between the stud welding process and the energy storage stud welding and the drawn arc stud welding. I hope that everyone will observe and improve together in the future work.
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