Abstract: Method and apparatus for welding studs to a workpiece are provided. When studs are welded to workpieces using a draw-arc, stud-welding technique, a coating of smut is sometimes deposited on the workpiece around the welded end of the stud. This coating detracts from the appearance and if the workpiece is covered with coating material, such as paint, the smut must first be removed, requiring an extra operation. It has been found that the coating of smut will not be deposited, if, during the welding cycle, fluid is carefully deposited on the weld area around the end of the stud where the weld occurs. This fluid consists of a small volume of low pressure air and an anti-smut liquid.

Abstract: Mobile apparatus for, on site, welding of rail retaining clip studs to existing railroad rail plates which includes a railway car assembly having wheel and axle assemblies and propulsion means to move the railway car assembly along the railway tracks. The railway car assembly further includes two carriage assemblies each of which carries two welding gun assemblies which project downwardly upon each side of the rail plate. The carriage assembly includes carriage actuator means for moving the carriage assembly both longitudinally and transversely of the rail plate to position the welding gun assemblies. A position and sensing control means is provided which includes a rail plate sensor which first senses the position of a rail plate to stop the railway car assembly and properly position the welding gun assembies with respect to the rail plate longitudinally thereof.

Abstract: A method and apparatus for welding studs to a workpiece are provided. When the studs are welded to workpieces using a drawn-arc, stud welding technique, sometimes a coating of smut is deposited on the workpiece around the welded end of the stud. This coating detracts from the appearance of the stud and workpiece. Further, if the workpiece is to be covered with a coating material, the coating of smut must first be removed, resulting in an extra operation. It has been found that the coating of smut will not be deposited if, during the stud welding cycle, gas is directed toward the weld area in a swirling manner around the end of stud where the weld occurs.

Abstract: Both process and apparatus are disclosed for testing arc stud welding guns. The process and apparatus are premised on generating two electric signals, the first of which occurs as a result of a switching action at the beginning of a welding operation. The second occurs when the welding stud impacts it's counter-electrode. The elapsed time between these signals is measured and used as a basis to determine the effectiveness of the arc stud welding gun. Process and apparatus are both disclosed for testing during actual and simulated arc welding.

Abstract: Method and apparatus are provided for welding studs to a work surface wherein a substantially smut free surface is produced adjacent the weld. Apparatus is provided for depositing a thin coating of liquid in spray form onto the work surface adjacent the area whereon the stud is to be welded, prior to the welding operation. Contaminates formed in suspension in the liquid during the welding operation are removed by removal of the liquid suspension which is accomplished in a simple and inexpensive manner.

Abstract: A stud welding method uses an inert mixed gas as arc shield in performing stud welding on a base metal, such as, vehicle body, by utilizing the stud, e.g. a T-stud, as an electrode, the stud serving as the positive pole while the base metal serves as the negative pole to thereby prevent formation of oxide film on the base metal surface during the welding, the inert mixed gas comprising carbon dioxide gas and argon gas.

Abstract: A fastener is provided for securing an article to a support without making a hole in the support and wherein access can be gained to only one side of the support. The fastener is welded to the accessible surface of the support and the article is clamped to the support by setting the fastener with a blind-riveting tool.

Abstract: A part of hard, weldable material which has been through drilled and tapped is sealed by stud welding a stud thereover to form a fluid-tight article which is used to facilitate the connecting of other parts. The threads are protected during stud welding by a conductive refractory insert in the tapped through bore thereby preventing molten metal or the like from entering the same. A magnetic jig serves to hold the insert and as an electrical connector of the insert to the part to permit the proper arc to be drawn during stud welding.

Abstract: An improved, relatively permanent operating head for stud welding guns is provided which eliminates the need of ferrule replacement after each welding sequence, thereby greatly speeding up and facilitating the welding operation, and lowering the cost thereof. The head includes an elongated, metallic, notched, dielectric-covered ferrule surrounding the usual stud-conveying chuck provided with the gun, along with air cooling apparatus for directing circumferentially spaced air currents through and exteriorly of the permanent ferrule to extend the life thereof and minimize buildup of slag thereon. In preferred forms, an inner, electrically insulating phenolic sleeve is disposed between the chuck and ferrule, and the work end of the latter is coated with an initial layer of tungsten carbide and an outer layer of tantalum for maximum heat resistance and electrical insulation.

Abstract: A fastener is provided for securing an article to a support without making a hole in the support and wherein access can be gained to only one side of the support. The fastener is welded to the accessible surface of the support and the article is clamped to the support by setting the fastener with a blind-riveting tool.

Abstract: An arc welding device is provided, which device is employed for the attachment of studs to a work surface. The device embodying the subject invention allows the operator to weld a stud on an area of a workpiece which has heretofore been inaccessible to prior art welding guns, of the type in common use. The aforesaid is generally accomplished by arrangement of the stud gripping collet relative to the operating elements of the device such that with the stud positioned normal to a work surface, the operating elements are off-set laterally from the stud.

Abstract: The apparatus for the automatic introduction of the members to the electrode of a resistance welding machine comprises an arm mounted on the machine frame so as to pivot about a horizontal pin located at the intersection of the horizontal hollow electrode axis and the vertical of the end of the slide for supplying the members to be welded, at least one jack for controlling the rotation of said arm, a finger mounted at the end of the arm so as to slide radially and coupled to at least one control jack integral with the arm, and a gripper mounted at the end of said finger and having two jaws which move under the action of at least one jack.A particular application of the invention is to the fitting of studs to heat exchanger tubes.

Abstract: Process for producing a component part of a railway switch or of a railway crossing in which frogs consisting of austenitic manganese steel casting are, with interposition of an intermediate piece, connected by a welding operation with rails consisting of carbon steel, characterized in that an intermediate piece is welded to the portions of the frog or of the component part of the railway crossing which are to be connected with the rails, and in that this intermediate piece consists of austenitic steel, whereupon the frog or the component part of the railway crossing is, together with the intermediate piece, heated to a temperature, preferably to about 1050.degree. C.

Abstract: A stud welding gun having means for automatically feeding studs to the barrel of the gun is provided with a stud receiver which facilitates removal of jammed studs from the device.

Abstract: A part structure adapted for attachment to a metal base by welding, particularly an ornament for attachment to an automobile body. The part structure or ornament is a metallic, electrically conductive member and has at least one weld stud affixed thereto. A resilient seal surrounds the weld stud and effects a seal around the weld stud and the weld produced thereby during welding.

Abstract: Relates to a method of and apparatus for electric welding through insulation coatings, such as paint, on metallic surfaces by directing a vapor jet of paint solvent upon a selected area of a painted metal surface to first soften and then vaporblast the softened paint away from the area to expose a bare spot of the metal surface for welding. Then, before the softened paint reflows back over the bare spot as a result of the discontinuance of the vapor jet, quickly bringing a metal part into welding range of the bare spot and welding the two metal parts together. Following the welding operation, the softened paint coating reflows over the exposed welded juncture and hardens to form a protective film thereover.

Abstract: A method and apparatus for welding studs to workpieces are provided. The invention is particularly concerned with welding studs to workpieces made of materials having relatively low electrical resistance but covered with layers of other materials having higher electrical resistance, a common example being metal workpieces having painted surfaces. In order for the stud to make effective electrical contact with the workpiece at the beginning of the welding cycle, the paint must be eliminated; in accordance with the invention, this is accomplished by rotating the stud which effectively removes the portion of the paint in contact with the stud. Electrical contact can then be established between the stud and the workpiece to enable the welding cycle to be initiated.

Abstract: In a bolt welding gun, a tubular bolt holder is positioned on the front end of the gun body and is threadedly connected to the tubular front part of a slide-in unit. The position of the bold holder is axially displaceable relative to the front part. A nut is threaded onto the bolt holder for fixing the position of the holder with relation to the front part. In addition, a base ring is mounted on the front end of the gun body and supporting legs for the gun extend outwardly from the ring. The base ring is coaxial with the nut and has a recess into which the nut fits for preventing its rotation. A releaseable lock within the gun body is engageable with the base ring and prevents its rotation and, as a result, the ring holds the nut against axial displacement for securing the position of the bolt holder relative to the tubular front part.

Abstract: A welding terminal operable to arc weld to a work piece a stud thereafter drive an element prethreaded to the stud. In one embodiment, the welding terminal may be adapted to cooperate with a guide to facilitate engagement with the prethreaded element, and in another embodiment, the welding terminal may have fluting or ribs to grippingly engage a portion of the prethreaded element. The duration of the arc weld and the sequencing of the welding and driving functions both may be automatically controlled. The normal force imposed on the fixed stud portion and the torque imposed on the movable threaded portion may be substantially automatically limited.

Abstract: The present invention is directed to an improved integral sheet metal welding pin particularly adapted for use with automatic welding machines of the type in which pins are stored in random fashion in a hopper. The pin incorporates a shank adapted to be attached by resistance welding to sheet metal ducting, and includes an enlarged head spaced from the duct and adapted to press insulation against the duct. The improved pin is characterized by an elongated tongue portion struck from the head of the pin and lying in parallel spaced relation to the shank, the configuration of the tongue and its location being such as to prevent stacking or nesting of weld pins in a manner which would preclude their being separated for automatic feeding, the tongue also serving as a stop in the course of welding, to preclude over-melting of the shank or damaging of the insulation.

Abstract: The welding of studs by a drop technique is provided, including provisions for the rapid feeding of the studs to a chuck. In this type of welding, a stud is held a predetermined distance above a workpiece with an electrical potential established therebetween. The stud is held in a chuck which, in turn, is carried by a ram. The stud, the chuck, and the ram are allowed to drop the predetermined distance to the workpiece, at which time the stud becomes fused thereto. Weights are often applied to the ram and the distance of the stud above the workpiece can be varied to achieve a proper weld for a particular workpiece. Means are provided to rapidly supply studs to the chuck and include a chuck leg forming a loading passage and carrying the chuck at an end thereof. A feed passage communicates with the side of the loading passage and feeds studs thereinto from a remote supply source. A back-up plunger is affixed directly to the ram and extends into the loading passage of the chuck leg.

Abstract: A welding tool is set forth for end welding studs to workpieces. The tool is primarily designed to end weld small studs having precisely-formed tips. The stud is held by a chuck connected to a chuck leg with an electrical coil holding the chuck leg in a retracted position prior to welding. When the coil is deenergized, a plunge spring plunges the chuck leg, the chuck, and the stud back toward the workpiece. With a high voltage imposed between the stud and the workpiece, the stud tip vaporizes when reaching the workpiece and adjacent portions of the stud and workpiece melt to securely weld the stud. To initially move the chuck and chuck leg to the retracted position, a retraction mechanism is provided. This includes a lever pivotally mounted at the front of the tool and engagable with a portion of the chuck leg to retract the chuck leg when the lever is manipulated by an operator. This reduces the retraction effort to increase the rate of welding and to reduce operator fatigue.

Abstract: A welding head is provided having a bore substantially larger than the sh of a rivet to be welded, and having a conical aperture for receiving the stud head. A copper-free sheath is disposed in the bore for receiving and locating the stud shank. In a preferred embodiment an associated magnet and switch are disposed within the welding head. When the stud-bearing head is brought into firm contact with a substrate current flows through the head, welding it to the substrate. The increased pressure upon the stud urges the magnet inwardly, operating the switch to control the equipment which locates the welding head.

Abstract: Small attachment members, such as clamps, mounting bars, identification plates, lugs and the like, are formed of shaped walls with at least one welding projection stamped from the wall arranged a contact the metallic base which projection limits the arc in condenser-discharge welding of the attachments and a punctiform projection centrally disposed on and extending outwardly from the welding projection is used for starting and controlling the condenser-discharge welding operation.

Abstract: Boiler tube studs and a method of welding the studs to boiler tubes are provided. Boiler tubes have a multiplicity of studs welded thereto and extending outwardly therefrom, with refractory material placed over the studs and held thereon to protect the boiler tubes and to prevent deterioration and wear thereof. The studs wear down over a period of time and new studs have to be welded to the tubes periodically. In accordance with the invention, the new studs are welded directly on the worn studs or nubbins without the necessity of grinding down or otherwise removing or partially removing the worn studs. The new studs have recesses in the ends to facilitate being positioned on the old studs in proper welding position and to improve the welding operation.

Abstract: A ceramic fiber mat attached to the interior wall or surface of a high temperature chamber of furnace or adapted to overlie an intermediate insulating member positioned between the mat and a furnace wall, the fibers in the mat lying in planes generally perpendicular to the wall, the mat constituting an improved insulation for the wall where the interior of the chamber or furnace will be operating at temperatures in excess of 1600.degree. F.

Abstract: In combination with conventional apparatus for joining members of aluminum or other electrically conducting material by resistance welding, adjustable supports for arranging the work-contacting electrodes in spaced proximity to the work, and circuitry for inducing an inert gas shielded arc of alternating current across each electrode and the work, the apparatus being operable to effect self-cleaning of the electrodes as well as the work between successive welding operations.

Abstract: A conventional stud-welding gun has been modified to allow it to be used for welding under water. The stud is contained within a water-tight enclosure formed at the end of the gun by pressing the seal at the end against the object to which the stud is to be welded. A water pump evacuates the enclosure and a stream of inert gas is provided to expel water and dry the region where the weld is to occur.

Abstract: An article of manufacture having a synthetic, thermoplastic substructure, a metallic plating on the external surface of the substructure, and a metallic stud joined to the article in contact with the plating, is adapted to be electrically welded to a metallic supporting structure, whether or not the surface of the structure to which the article is to be welded is coated with an electrically nonconductive material, and a sealing of the area of the structure adjacent the welded joint is effected during the welding operation, with the material forming the seal having derived from the body of the substructure.