Abstract: A weld-on part made of aluminum or an aluminum alloy, such as but not limited to a stud (1), which has a surface which is at least partially provided with a layer (5) which contains a titanium containing material. The stud (1) is treated with a chrome-free passivating solution which imparts corrosion resistance while simultaneously causing a layer (5) of titanium containing material to be formed on at least a portion of the surface of the stud (1). The layer (5) of titanium containing material permits the stud (1) to be satisfactorily welded to a surface, without the occurrence of arc jumping or blowing, in part, by lowering contact resistance during the welding process.

Abstract: Proposed is a device for welding metal elements, in particular studs, to structural parts, having a welding head that has a collet chuck for the accommodation of an element, having a feed unit for the feed of elements into the chuck, and having a power supply means for the supply of electric energy for a welding procedure. The chuck has at least two segments electrically insolated from one another. It can be detected via an applied test voltage whether a metal element to be welded is located in the chuck.

Abstract: The invention concerns a feed device (1) comprising a positioning piston (6) for holding a fastening element (2) during positioning, a catching clamp (5) for pre-positioning the fastening element (2) for the positioning piston (6) and a housing (3) for holding the positioning piston (6) and the catching clamp (5), the housing (3) having a feed channel (4) for feeding the fastening element (2) to the catching clamp (5) and the positioning piston (6) being adjustable for positioning the fastening element (2) relative to the housing (3), and the catching clamp (5) being able to be closed or opened substantially independently of the axial forward movements of the fastening element (2) during forward and backward movement of the positioning piston (6).

Abstract: An appartus and method for a stud welder power source is disclosed. The power source has a control circuit connected to an inverter which converts an electrical signal from a power source into an electrical signal that can perform stud welding. The inverter conditions the power signal such that a current of at least 1000 amps can be generated nearly instantaneously. Additionally, having a power source that includes a control circuit with an inverter allows for a smaller and lighter appartus when compared to known stud welders.

Abstract: A hand welding device for short-time arc welding of elements, such as metal studs, onto parts, such as metal sheets, having a handlable housing, a holding means mounted on the housing to hold an element to be welded onto a part, a reciprocating means mounted on the housing to advance and restore the holding means relative to the housing, and positioning means mounted on the housing to maintain a predetermined distance from the part, is proposed. Further, a corresponding welding apparatus having such a hand welding device and a welding gauge fastened to the part, are proposed.

Abstract: A short-cycle arc-welding system (10) and a method for welding elements (32), such as metal bolts (32) to components (34) such as sheet metal (34) includes a robot (12), having at least one arm (16) displaceable on at least two co-ordinate axes (x, y, z), a welding head base (20) fixed to robot arm (16), a welding head (22) displaceably mounted on welding head base (20), a retaining device (30) retaining an element, a lifting device (36) for setting and re-positioning retaining device (30) in relation to welding head (22), and a measuring system (44,46) determining the relative position between component (34) and element (32). Measuring system (44,46) has a control device (46), controlling lifting device (36) such that element (32) displaces towards component (34) until contacting component (34) to determine the relative position.

Abstract: The invention relates to a method for welding a bolt (19) onto a workpiece, using a bolt-welding device and to a bolt-welding device. A force is applied to the drive shaft (11) using a switchable unit (29), said force exerting a resistance against a displacement of the drive shaft (11). The drive shaft (11) is moved by an electromagnetic linear drive (5) acting in an axial direction. The unit (29) can prevent the movement of the drive shaft (11) and can fix the latter in position, in such a way that the linear drive (5) can be switched to a currentless state. In addition, the unit can dampen the movement of the drive shaft (11).

Abstract: A fastening system is providing, the fastening system has a weld stud having an annular weldment portion and a fracturable nut. The fracturable nut and stud construction is configured to fail under torsional load prior to the structural parts failure.

Abstract: The invention relates to a multiple stage method for arc-welding a bolt (3) to a metal structure (1), said bolt (3) having a flange (5) at the end that is to be welded on. The actual welding process is preceded by a cleaning method that is carried out by means of an arc. Said cleaning method consists of two or more stages. It is crucial to control the arc and the distance between the bolt (3) and the structure surface (7) in such a way that only cleaning takes place, without causing premature welding. While during the first cleaning state, only a small surface is cleaned intensively, in the second stage, a larger surface is cleaned due to a greater distance between the bolt (3) and the structure surface (7). Separation through interruption of the arc and maintenance of the bolt (3) in a stationary position at a distance from the structure surface (7) must take place between the first and second cleaning stages.

Abstract: The invention relates to a rapid arc welding system (10) for welding elements (12) onto components (14). The inventive system comprises a welding head (16), a supply device (24) for supplying elements (12) to the component (14) and a control and power device (20). Said control and power device comprises a safety circuit for controlling the safety functions of the welding system (10) which allows an operation that is especially safeguarded from unauthorized use of the system in which an operation disruption is partially cancelled. In this partial operation mode, individual components of the system (10) can be activated selectively, especially for the purpose of maintenance.

Abstract: A stud welding gun includes a closed conductivity path indicating a stud properly positioned for welding. Another aspect includes a conductivity detection circuit closed when a stud is present. A further aspect provides a method to operate a stud welding gun including closing a conductivity path to permit a welding operation. A still further aspect provides a method to detect a stud presence by passing a conductivity current from a conductivity detection circuit through a conductivity path closed by a stud.

Abstract: The invention relates to a short-cycle arc welding system comprising a robot having at least one arm which can be displaced in at least one coordinate axis (x, y, z), a welding head which is positioned on the arm and on which a holding device or holding an element and a lifting device are provided, said lifting device moving the holding device back and forth in relation to the welding head and a measuring system for determining the relative position between a component and an element which is held by the holding device and is to be welded to the component. Said measuring system comprises a foot which is mounted on the welding head and which is embodied in such a way that, during operation, it is in contact with the component in order to determine the relative position between the element and the component.

Abstract: A process and a system are proposed for short-time arc welding elements, such as for example metal studs, on to components, such as for example metal sheets, wherein an element in the context of a welding operation is initially raised in relation to the component, a welding arc is formed between the element and the component, and the element is lowered again, the lifting height of the element in relation to the component being detected at least within a time segment between raising and lowering of the element.

Abstract: A process and a system are proposed for short-time arc welding, in particular for stud welding, with the step of sampling a welding parameter, in particular the arc voltage (U), during at least one time segment (Ts) of the welding operation, in order to detect disturbances, wherein the measurement curve determined from the sampling operation is smoothed and subsequently wherein at least one tolerance curve is generated which lies at a previously adjustable distance from the smoothed measurement curve, and subsequently the unsmoothed measurement curve is compared with the tolerance curve in order to detect high-frequency disturbances.

Abstract: A method of welding a stud (11) is provided. In another aspect of the present invention, a welding system is provided for a weld stud (11). A further aspect of the present invention employs a weld stud (11) with a substantially conical end section (29).

Abstract: Proposed is a joining system (10) as well as a method of operating a joining system (10) for joining elements (20) onto components (22), in particular for the short-time arc welding of elements (20), such as metal studs (20), onto components (22), such as metal sheets (22), having a central unit (12), which comprises a control device (30) and connectable to which is at least one joining unit (14) from a selection of different joining units, each of which comprises at least two modules (16, 18). The control unit (30) is designed so as to recognise (S16, S28) the mutual compatibility of the at least two modules (16, 18) of a connected joining unit (14) as well as the compatibility of the connected joining unit (14) with the central unit (12).

Abstract: The present invention relates to a lift-and-strike welding process. In a first step, e.g. an aluminum surfaces (5) of a component is cleaned by striking an arc and then the element (4) to be connected is welded on by means of at least one second voltage. Besides a lift-and-strike welding apparatus, a further lift-and-strike welding process is also provided, wherein an electric cleaning current flows between a surface (5) of a component and an element to be welded thereon, in that the component rests on the surface (5) and then the element (4) is lifted off the surface (5) up to an approximately, in terms of time, constant distance for removing a coating from the surface (5) by means of an arc, then the current changes its polarity, wherein afterwards at least one welding current is produced and then the element (4) is welded to the surface (5).

Abstract: A fastening system is providing, the fastening system has a weld stud having an annular weldment portion and a fracturable nut. The fracturable nut and stud construction is configured to fail under torsional load prior to the structural parts failure.

Abstract: The invention relates to a stud welding head with a linear drive (5), a welding pin (11) coupled with said linear drive (5), and a length metering system (7) that determines the position of the welding pin (11) in the stud welding head, said length metering system (7) being an electromagnetic length metering system.

Abstract: A welding device includes a holder for a weld part (1) adapted to be moved substantially perpendicularly to, and away from, a surface of a workpiece (2) on which the weld part (1) is to be welded. An arc producing system produces an arc between the weld part (1) and the surface of the workpiece (2) with the arc generating a magnetic flux. A field former (3) includes a low-retentivity steel and provides a flux path for the magnetic flux generated by the arc.

Abstract: A stud welder utilizing a frequency inverter which is capable of delivering in access of 1000 A for a short duration of about 1 second using double-sided cooled power semiconductors. The inverter can deliver constant power to the stud circuit or the arc, sense the progress of the stud process, and stop the process if the forecast for an acceptable stud will not be achieved, and detected sufficiently early that the current has not created a stud that can not be removed and repeated. The stud welder also has a circuit capable of delivering a high voltage pulse capable of penetrating paint covering the base metal, and thereby enabling better stud welding to painted material. The stud welder and method also monitor the ending energy delivered and adjust it to the energy required. The stud welder further has a battery or capacitor storage device to reduce the fuse size used by storing the energy needed when a stud is formed by charging the storage device when no power is needed.

Abstract: A device and a method for short-cycle arc welding of elements (26) to components are disclosed, with a positioning mechanism (14) that holds a welding head (28) and can be positioned relative to a component (12), wherein the welding head (28) has a chucking mechanism (32) for holding an element (26), a linear motion mechanism (58) for advancing and retracting the chucking mechanism (32) relative to the welding head (28), and a feed channel (30) for feeding elements (26) to be welded into the chucking mechanism (32). The chucking mechanism (32) has radially movable chucking elements (34) that can be moved by a chucking means between an open position which permits axial passage of an element (26) from the feed channel (30) through the chucking device, and a chucking position in which an element (26) is chucked between the chucking elements (34).

Abstract: According to a first embodiment of the method, the stud holder is first positioned without a part to be welded at a certain distance from the tool surface. A part to be welded is then provided. When the welding axle moves towards the workpiece, the path that needs to be travelled in order to bring the part to be welded and the workpiece into contact is detected. Conclusions regarding the presence or absence of a part to be welded are then drawn, based on the previous distance between the stud holder and the workpiece and the path travelled. According to another embodiment, the stud holder is moved towards the workpiece with a part to be welded until contact is detected. If, after contact is detected, further movement of the welding axle is possible as a result of the part to be welded being pushed into the stud holder, this is interpreted as an indication of the presence of a part to be welded.

Abstract: Proposed is a device for welding metal elements, in particular studs, to structural parts, having a welding head that has a collet chuck for the accommodation of an element, having a feed unit for the feed of elements into the chuck, and having a power supply means for the supply of electric energy for a welding procedure. The chuck has at least two segments electrically insolated from one another. It can be detected via an applied test voltage whether a metal element to be welded is located in the chuck.

Abstract: The invention relates to a method of manufacturing a welding stud from a wire by cold-working and by hardening and tempering. The welding stud particularly serves to be welded to a workpiece by means of an electric stud welding method and consists of a mounting portion and a welding portion. According to the invention, the wire is first pre-treated by hardening and tempering and is then cold-worked in such a way that the mounting portion and the welding portion have different strengths.

Abstract: For arc welding a sleeve 3 to a workpiece surface 2, a sleeve holder 1 is surrounded by a field-former unit which contains a magnet coil 4, a magnetic flux return member 6 and a field former 7. A magnetic field is generated with a field component extending radially to the sleeve 3 within the welding gap to set the arc in rotation. To ensure a constant magnetic flux, the field-former unit, in particular its magnet coil 4, is cooled by a temperature-controlled cooling medium circulated through the welding head.

Abstract: A stud welder utilizing a frequency inverter which is capable of delivering in access of 1000 A for a short duration of about 1 second using double-sided cooled power semiconductors. The inverter can deliver constant power to the stud circuit or the arc, sense the progress of the stud process, and stop the process if the forecast for an acceptable stud will not be achieved, and detected sufficiently early that the current has not created a stud that can not be removed and repeated. The stud welder also has a circuit capable of delivering a high voltage pulse capable of penetrating paint covering the base metal, and thereby enabling better stud welding to painted material. The stud welder and method also monitor the ending energy delivered and adjust it to the energy required. The stud welder further has a battery or capacitor storage device to reduce the fuse size used by storing the energy needed when a stud is formed by charging the storage device when no power is needed.

Abstract: A welding device includes a holder for a weld part (1) adapted to be moved substantially perpendicularly to, and away from, a surface of a workpiece (2) on which the weld part (1) is to be welded. An arc producing system produces an arc between the weld part (1) and the surface of the workpiece (2) with the arc generating a magnetic flux. A field former (3) includes a low-retentivity steel and provides a flux path for the magnetic flux generated by the arc.

Abstract: The invention relates to a method of manufacturing a welding stud from a wire by cold-working and by hardening and tempering. The welding stud particularly serves to be welded to a workpiece by means of an electric stud welding method and consists of a mounting portion and a welding portion. According to the invention, the wire is first pre-treated by hardening and tempering and is then cold-worked in such a way that the mounting portion and the welding portion have different strengths.

Abstract: The invention relates to a stud welding head with a linear drive (5), a welding pin (11) coupled with said linear drive (5), and a length metering system (7) that determines the position of the welding pin (11) in the stud welding head, said length metering system (7) being an electromagnetic length metering system.

Abstract: A blow feed weld gun for welding a nut to a metal substrate is disclosed. The blow feed weld gun has an air feed mechanism and a nut drive mechanism. The nut drive mechanism contains a primary piston assembly located within a cylindrical working chamber. The primary piston assembly is coupled to a first driven piston which is hollow and defines a passage which welding gasses and/or air can be delivered to the threads of a threaded weld nut.

Abstract: A blow feed weld gun for welding a nut to a metal substrate is disclosed. The blow feed weld gun has an air feed mechanism and a nut drive mechanism. The nut drive mechanism contains a primary piston assembly located within a cylindrical working chamber. The primary piston assembly is coupled to a first driven piston which is hollow and defines a passage which welding gasses and/or air can be delivered to the threads of a threaded weld nut.

Abstract: The invention relates to a multiple stage method for arc-welding a bolt (3) to a metal structure (1), said bolt (3) having a flange (5) at the end that is to be welded on. The actual welding process is preceded by a cleaning method that is carried out by means of an arc. Said cleaning method can be advantageously carried out in two or more stages with different effects. It is crucial to control the arc and the distance between the bolt (3) and the structure surface (7) in such a way that only cleaning takes place, without causing premature welding. While during the first cleaning state, only a small surface can be cleaned intensively, in the second stage, a large surface can be cleaned due to a greater distance between the bolt (3) and the structure surface (7). Separation through interruption of the arc and maintenance of the bolt (3) in a stationary position at a distance from the structure surface (7) must take place between the first and second cleaning stages.

Abstract: A resistance weld pin for connecting batts of insulation to the interior of ducts is disclosed, the pin having superior aerodynamic properties which minimize turbulence in the duct flow stream and reduce the tendency of increments of the insulation surrounding the pin will become separated from the main body of the bott when introduced into the air stream. The pin assembly comprises a washer and a pin component projecting through the washer. The upper surface of the washer includes an annular depressed trough surrounding the head of the pin. Preferably the head is disposed within a central depression in the washer, the upper surface of the head forming a contact surface for the applying electrode and lying in a plane above an annular platform extending between the trough and the depression.

Abstract: A stud welding gun for alternatively welding studs of a first and second length to base members. The gun includes a stud feed member for moving a stud toward a stud holder. The gun further includes at least two stud cartridges each having a plurality of studs in side by side array and opposed end walls extending between first and second side walls. A first cartridge has end walls spaced a distance equal to studs having the first length. A second cartridge has end walls spaced a distance equal to studs having the second length. At least one of the side walls of each cartridge extends to a pre-determined overall length. A housing is adapted to receive the cartridges placing the studs in the path of the stud feed member. The gun includes a stud mover that sequentially moves the studs into the path of the stud feed member.

Abstract: A process and apparatus for welding a metal component (28) to a metal workpiece (40). The component (28) typically comprises a metal weld region (36) and a threaded connector region and the apparatus includes a weld head comprising a nozzle (8) for holding the weld region (36) of the component (28) adjacent the workpiece (40). The weld head induces a weld arc between the weld region (36) of the component (28) and the workpiece (40) to create a weld pool of molten material. The weld head subsequently moves the weld region into the weld pool to permanently join the component (28) to the workpiece (40). The apparatus further comprises a pressurised fluid source and a fluid flow control means for directing the pressurised fluid between the weld head and the component and weld pool so as to deflect any airborne fluid residue of the weld pool away from the connector region of the component (28).

Abstract: Apparatus and process for safely welding a stud into an overhead workpiece that includes a ferrule having an interrupted perimeter surrounding the stud for contact with the overhead workpiece and a support assembly for connection to a stud gun including a shield surrounding the support assembly and having a continuous perimeter defining a free space by being spaced from the stud and wherein the free space is in communication with the interrupted perimeter of the ferrule. The free space has a width and depth sufficient to receive and contain all molten substances produced during the welding. A fire resistant material is positioned within the free space to hold all these molten substances to thereby safely protect the operator of the stud gun from the gravity induced falling molten substances.

Abstract: A disposable collet adapter for attaching a workpiece to a stud welding tool. One end of the resilient collet adapter slideably mounts to one end of a workpiece and the opposed end slideably attaches to the electrode of the stud welding tool. The opposed ends of the collet adapter are individually tailored so that of the workpiece and the electrode may have distinct cross-sectional profiles. After a welding operation, the collet adapter can be discarded or reused.

Abstract: Apparatus and methods for arc welding a stud to a workpiece without the use of a ferrule are disclosed. Apparatus according to the invention include a stud arc welding gun having a spacer at a distal end thereof, and a chuck adapted to receive a stud having a diameter of more than about ⅜ inch. A stud feeding device is coupled to the gun for automatically loading studs into the gun. The stud feeding device can include a bowl feeder and a stud feeding conduit via which studs are transferred from the bowl feeder to the stud gun. A gun positioning device, such as an arm of a robot, is coupled to the gun, and automatically positions the gun such that the spacer is against a receiving surface of the workpiece. A controller coupled to the stud gun initiates a stud arc welding process to arc weld the stud to the workpiece.

Abstract: A fastening element for fastening on or in a component, in particular a T-stud or punch rivet, has a fastening end. The fastening element has, at a guide end remote from the fastening end, a recess for receiving a tool end piece which fits into the recess and by means of which the fastening element can be positioned.

Abstract: The invention relates to a stud welding device with an adjustment member (3), displaceable axially forward and backwards, a stud holder (2), connected to the adjustment member (3), so the movement thereof is transmitted to the stud holder (2), a drive unit (4), having a coil (15) which can be connected to a source of current, the coil being rigidly attached to a hollow body (14) connected to the adjustment member (3), which hollow body is arranged as axially movable in an air gap between a magnetisable core (8) and a magnetisable casing, and with a compression spring (19) acting on the adjustment member (3), pressing this into an end position defined by a buffer (23, 57), wherein the core (8) has a recess (45), extending from a front face (48) adjacent to the adjustment member (3) over at least a part of the axial length of the core (8), into which the compression spring (19) partially protrudes, wherein the recess (45) is designed as coaxial to the adjustment member (3).

Abstract: A cover for a transmission torque connector having loosened or otherwise damaged bolts is repaired for reuse. One method includes removing a loosened bolt, and plugging and countersinking the bolt hole. The countersunk area on the exterior of the cover provides an area to form a welding bead to permanently seal the whole. The surface is then prepared for welding a stud onto it to complete the repair. In the case where the original bolt is damaged but has not been loosened, the top part of the bolt can be cut off so that the bolt can serve as the plug.

Abstract: A stud welding gun for alternatively welding studs of a first and second length to base members. The gun includes a stud feed member for moving a stud toward a stud holder. The gun further includes at least two stud cartridges each having a plurality of studs in side by side array and opposed end walls extending between first and second side walls. A first cartridge has end walls spaced a distance equal to studs having the first length. A second cartridge has end walls spaced a distance equal to studs having the second length. At least one of the side walls of each cartridge extends to a pre-determined overall length. A housing is adapted to receive the cartridges placing the studs in the path of the stud feed member. The gun includes a stud mover that sequentially moves the studs into the path of the stud feed member.

Abstract: To form a welded joint between a fastening means (1) and a structure (2), a fastening means (1) with a holder (3) and a connecting element (4) is proposed. The holder (3) essentially consists of an electrically insulating material. The connecting element (4) consists of a substantially electrically conductive material. The holder (3) substantially surrounds the connecting element (4). The connecting element (4) has a contact face (5) located inside the holder (3). The holder (3) has a through-orifice (6) at least partially overlapping the contact face (5). A contact piece (7) of an electrically operated welding device is introduced through the through-orifice (6).

Abstract: A conventional stud welding tool is substantially improved by providing the tool with an electrode with an adjustable aperture capable of grasping studs with a variety of sizes. The adjustable aperture is in the form of a chuck having a plurality of sliding fingers movable along intersecting axes and positionable along these axes to form an aperture of a desired diameter. The fingers have a threaded exterior surface, and the chuck includes a wheel having a threaded interior surface for engaging the threaded exterior surfaces of the fingers for moving the fingers along their axes in response to rotation of the wheel. The chuck is automatically closed and opened by a control circuit in response to the condition of a variety of sensors connected to the control circuit. Also, a collating strip of studs and a feed assembly is used to automatically deliver studs to the electrode under control of the control circuit.

Abstract: Stud welding device with an axially displaceable adjusting element (3, 17) for displacement from a front position into a rear position and back, in which a magnetic field and a coil (15) interact in such a way that, when the coil (15) is connected to a controllable current source (41) an axial force is produced in order to displace the adjusting element (3, 17), the movement of which is transmitted to a stud holder (2), characterized in that the coil (15) is rigidly arranged on a hollow body (14) which is connected to the adjusting element (3, 17) and is arranged axially movably in an air gap (13) between a magnetizable core (8) and a magnetizable sheath (10), the magnetic field being conveyed via at least one yoke (9) connecting the core (8) and the sheath (10) while passing radially through the coil (15), the coil exerting on the adjusting element (3, 17) an axial force acting only in one direction as a function of the direction of current during current control.

Abstract: A stud welding gun (20) includes a barrel (42) which extends outward from a handle assembly (24). A chuck (46) on an outer end portion of the barrel (42) holds a stud (22) while the stud is being welded to a base member. A stud feed member (76) is manually moved along the barrel (42) from a retracted position to an extended position to sequentially feed studs (22) in a linear array (110) to the chuck (46). The stud feed member (76) has a leading end portion (124) which applied force against a trailing stud (22) in the array (110) of studs to move a leading stud (22) in the array of studs into the chuck (46). A detent (154) is engageable with a trailing stud (22) in the array (110) of studs to hold the array of studs against movement in a direction away from the chuck (46).

Abstract: A stud welding gun (20) includes a frame (36) which extends outward from a handle assembly (24). A chuck (46) on an outer end portion of the frame holds a stud (22) while the stud is being welded to a base member. A stud supply (60) is connected with the frame (36) and includes a housing (64) which receives a stud retainer or magazine (70) containing a linear array (72) of studs (22) disposed in a side-by-side relationship. The studs (22) are fed from the retainer (70) in the stud supply housing (64) to a receiving location (62). A stud feed member (76) is manually moved from a retracted position to an extended position to sequentially feed studs (22) to the chuck (46). The size of a linear slot (88) in the stud supply housing (64) can be varied to enable retainers (70) containing studs (22) of different lengths to be positioned in the stud supply housing.

Abstract: A system for automatically feeding studs to the electrode of a manual stud welding tool. The system comprises a magazine associated with the tool. The magazine receives a tandem row of studs mounted in and collated by a disposable mounting and collating strip assembly. A drive assembly is associated with the magazine to advance the mounting and collating strip assembly such that each stud, when it becomes the forwardmost stud of the tandem row, is properly positioned with respect to the tool to be welded to a workpiece.

Abstract: A new adjustable collet for stud welding employs a plurality of electrically energizable jaws coordinated to firmly grasp studs of various shapes, sizes and orientations while welding them to a work surface. This adjustable collet will also ensure better contact with the stud and thus reduce the likelihood of arcing and faulty welds. Premature collet wear will also be averted by reducing the amount of sliding contact between the collet and the stud.