Abstract: A concrete wall frame assembly and a method of manufacturing same is disclosed. The assembly includes two generally parallel metal plates and at least one rod extending between a first end and a second end. A first end of the rod is passed through a hole in the second plate toward the first plate until the first end engages a continuous inner surface of the first plate. The second end of the rod protrudes through the hole and extends past an outer surface of the second plate. A stud welder is connected to the either the second, protruding end of the rod, or connected to the rod between the two metal plates to stud weld the first rod end to the inner surface of the first plate. The second end of the rod is then arc welded to the second metal plate at the outer surface.

Abstract: A stud weldable rebar includes a steel bar comprised of a material composition confirming to ASTM 706 which extends along an axis A from a first end to a second end. The steel bar includes a base portion disposed adjacent the first end which has a base diameter D1 to define a base cross-sectional area of the base portion. The steel bar also includes an upset portion disposed adjacent the second end which has an upset diameter D2 being greater than said base diameter D1 to define an upset cross-sectional area of said upset portion. The material composition of the steel bar is restricted to a carbon equivalency between 0.31 and 0.43, and the upset cross-sectional area is approximately 13.5% to 22.5% greater than the base cross-sectional area to provide A706 rebar that surprisingly meets both the AWS D1.1 and ACI 318 standards after stud welding.

Abstract: A weld stud including a shank that has a reduced diameter portion, and a larger diameter portion. A weld base is defined on the reduced diameter portion and a flange is positioned on the larger diameter portion. A bore wall extends axially through a face of the flange and into the larger diameter portion. The bore wall has a threaded portion that has a threaded diameter for receiving a fastener. A base diameter of the weld base is smaller than a larger diameter of the larger diameter portion and substantially equal to, or smaller than the threaded diameter. The threaded portion is axially spaced from the face of the flange by a first unthreaded portion, which defines a first unthreaded diameter that is larger than the threaded diameter. These features limit the loads transmitted to the fastener, thus allowing the weld stud to withstand shock loads to prevent fastener failures.

Abstract: A stud weldable rebar includes a steel bar comprised of a material composition confirming to ASTM 706 which extends along an axis A from a first end to a second end. The steel bar includes a base portion disposed adjacent the first end which has a base diameter D1 to define a base cross-sectional area of the base portion. The steel bar also includes an upset portion disposed adjacent the second end which has an upset diameter D2 being greater than said base diameter D1 to define an upset cross-sectional area of said upset portion. The material composition of the steel bar is restricted to a carbon equivalency between 0.31 and 0.43, and the upset cross-sectional area is approximately 13.5% to 22.5% greater than the base cross-sectional area to provide A706 rebar that surprisingly meets both the AWS D1.1 and ACI 318 standards after stud welding.

Abstract: A weld stud including a shank that has a reduced diameter portion, and a larger diameter portion. A weld base is defined on the reduced diameter portion and a flange is positioned on the larger diameter portion. A bore wall extends axially through a face of the flange and into the larger diameter portion. The bore wall has a threaded portion that has a threaded diameter for receiving a fastener. A base diameter of the weld base is smaller than a larger diameter of the larger diameter portion and substantially equal to, or smaller than the threaded diameter. The threaded portion is axially spaced from the face of the flange by a first unthreaded portion, which defines a first unthreaded diameter that is larger than the threaded diameter. These features limit the loads transmitted to the fastener, thus allowing the weld stud to withstand shock loads to prevent fastener failures.

Abstract: An underwater fastener welding apparatus that includes a welding tool positioned within a watertight housing. The housing includes an inlet coupled to a source of pressurized gas. The housing is pressurized to balance a pressure internal to and external to the housing when the underwater welding apparatus depth level is changed.

Abstract: A chuck assembly for a stud welding gun includes a current passing member parallel to and separated from an electrically isolated member forming a stud retaining gap. The current passing member provides a path for a welding current and includes a contact surface for releasably retaining and transmitting the welding current through a shank of a weld stud. The welding current only passes through the current passing member into the shank of the stud.

Abstract: A weld stud includes a cylindrical body having an outer surface and opposing first and second ends. At least one groove is formed in the outer surface of the cylindrical body. The groove extends helically about the cylindrical body from the first end toward the second end of the cylindrical body. A thread is formed on the cylindrical body and extends longitudinally from the first end towards the second end of the cylindrical body. The thread projects radially outward from the cylindrical body.

Abstract: A weld stud includes a cylindrical body having an outer surface and opposing first and second ends. At least one groove is formed in the outer surface of the cylindrical body. The groove extends helically about the cylindrical body from the first end toward the second end of the cylindrical body. A thread is formed on the cylindrical body and extends longitudinally from the first end towards the second end of the cylindrical body. The thread projects radially outward from the cylindrical body.

Abstract: Disclosed is a stud for a boiler or other high temperature application, such as a furnace. The stud is made of an iron aluminum alloy which comprises about 81 to 91 wt. % iron, about 8 to 13 wt. % aluminum, about 0.01 to 0.3 wt. % carbon, and zero to about 3 wt. % of a refractory metal and/or zero to about 1.5 wt. % zirconium. The studs are welded to a surface of a component of the boiler or furnace by arc or resistance welding. The aluminum of the iron aluminum alloy imparts good oxidation and sulfidation resistance to the studs. The alloy also has a good electrical resistance which makes the alloy especially useful for arc or resistance welding. The aluminum content acts as a getter to eliminate gas porosity in the resulting welds. The present invention is particularly useful for making boiler heat exchange surfaces or refractory covered surfaces wherein the studs function as refractory anchors.